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INTERNATIONAL
LIBRARY OF TECHNOLOGY
A SERIES OF TEXTBOOKS FOR PERSONS ENGAGED IN THE ENGINEERING
PROFESSIONS AND TRADES OR FOR THOSE WHO DESIRE
INFORMATION CONCERNING THEM. FULLY ILLUSTRATED
AND CONTAINING NUMEROUS PRACTICAL
EXAMPLES AND THEIR SOLUTIONS
COTTOIN
PICKERS
COTTON CARDS
DRAWING ROLLS
RAILWAY HEADS AND DRAWING FRAMES
COMBERS
FLY FRAMES
SCRANTON:
INTERNATIONAL TEXTBOOK COMPANY
TO
Copyrigrht, 1906, by International Textbook Company.
Entered at Stationers' Hall, London.
Cotton: Copyright, 1901. by Christopher Parkinson Brook-S. Copyright, 1905. by
International Textbook Company. Entered at Stationers' Hall, London.
Pickers, Part 1: Copyright, 1898, 1899, by Christopher Parkinson Brooks. Copy-
right, 1905, by International Textbook Company. Entered at Stationers'
Hall, London.
Pickers, Part 2: Copyright, 1899, by Christopher Parkinson Brooks. Copyright,
190.5, by International Textbook Company. Entered at Stationers' Hall,
London.
Cotton Cards: Copyright, 1899, by Christopher Parkinson Brooks. Copyright,
1905, by International Textbook Company. Entered at Stationers' Hall,
London.
Drawing Rolls: Copyright, 1899, by Christopher Parkinson Brooks- Copyright,
1903, by International Textbook Company. Entered at Stationers' Hall,
London.
Railway Heads and Drawing Frames: Copyright, 1899. by Christopher Parkinson
Brooks. Copyright, 1905, by International Textbook Company. Entered at
Stationers' Hall, London.
Combers: Copyright, 1899, by Christopher Parkinson Brooks. Copyright, 1905,
by International Textbook Company. Entered at Stationers' Hall, London.
Fly Frames: Copyright. 1899, by Christopher Parkinson Brooks. Copyright,
1905, by International Textbook Company. Entered at Stationers' Hall,
London.
All rights reserved.
PrintkI) in the United States.
PREFACE.
The International Library of Technology is the outgrowth
of a large and increasing demand that has arisen for the
Reference Libraries of the International Correspondence
Schools on the part of those who are not students of the
Schools. As the volumes composing this Library are all
printed from the same plates used in printing the Reference
Libraries above mentioned, a few words are necessary
regarding the scope and purpose of the instruction imparted
to the students of — and the class of students taught by —
these Schools, in order to afford a clear understanding of
their salient and unique features.
The only requirement for admission to any of the courses
offered by the International Correspondence Schools, is that
the applicant shall be able to read the English language and
to write it sufficiently well to make his written answers to
the questions asked him intelligible. Each course is com-
plete in itself, and no textbooks are required other than
those prepared by the Schools for the particular course
selected. The students themselves are from every class,
trade, and profession and from every country; they are,
almost without exception, busily engaged in some vocation,
and can spare but little time for study, and that usually
outside of their regular working hours. The information
desired is such as can be immediately applied in practice, so
that the student may be enabled to exchange his present
vocation for a more congenial one, or to rise to a higher level
in the one he now pursues. Furthermore, he wishes to
obtain a good Avorking knowledge of the subjects treated in
the shortest time and in the most direct manner possible.
iii
iv PREFACE
In meeting these requirements, we have produced a set of
books that in many respects, and particularly in the general
plan followed, are absolutely unique. In the majority of
subjects treated the knowledge of mathematics required is
limited to the simplest principles of arithmetic and mensu-
ration, and in no case is any greater knowledge of mathe-
matics needed than the simplest elementary principles of
algebra, geometry, and . trigonometry, with a thorough,
practical acquaintance with the use of the logarithmic table.
To effect this result, derivations of rules and formulas are
omitted, but thorough and complete instructions are given
regarding how, when, and under what circumstances any
particular rule, formula, or process should be applied; and
whenever possible one or more examples, such as would be
likely to arise in actual practice — together with their solu-
tions — are given to illustrate and explain its application.
In preparing these textbooks, it has been our constant
endeavor to view the matter from the student's standpoint,
and to try and anticipate everything that Avould cause him
trouble. The utmost pains have been taken to avoid and
correct any and all ambiguous expressions — both those due
to faulty rhetoric and those due to insufficiency of statement
or explanation. As the best way to make a statement,
explanation, or description clear is to give a picture or a
diagram in connection with it, illustrations have been used
almost without limit. The illustrations have in all cases
been adapted to the requirements of the text, and projec-
tions and sections or outline, partially shaded, or full-shaded
perspectives have been used, according to which will best
produce the desired results. Half-tones have been used
rather sparingly, except in those cases where the general
effect is desired rather than the actual details.
It is obvious that books prepared along the lines men-
tioned must not only be clear and concise beyond anything
heretofore attempted, but they must also possess unequaled
value for reference purposes. They not only give the maxi-
mum of information in a minimum space, but this infor-
mation is so ingeniously arranged and correlated, and the
PREFACE V
indexes are so full and complete, that it can at once be
made available to the reader. The numerous examples and
explanatory remarks, together with the absence of long
demonstrations and abstruse mathematical calculations, are
of great assistance in helping one to select the proper for-
mula, method, or process and in teaching him how and
when it should be used.
Six of the volumes comprising this library are devoted to
the subject of textile manufacturing. This volume, the first
of the series, considers the cotton fiber and the processes
through which cotton fibers have to pass before they can be
spun into yarn. After describing the growth, characteristics,
and the various classes of cotton, together with the action of
the cotton gin, bale breakers, and pickers, consideration is
given to the judging and mixing of cotton. Next, the
important subject of cotton cards is taken up; a detailed
description is given of card clothing and the action of the
various parts of a cotton card. Several types of cotton cards
are described, also the grinding and setting of these machines.
Drawing rolls, which play such important parts in all these
processes, are considered in detail, as regards both construc-
tion and setting. Then come drawing frames with their
various stop-motions, combers, and finally fly frames. Of
the latter, English as well as American types are shown and
detailed information presented as regards calculations for
producing the required hanks and twists.
The method of numbering the pages, cuts, articles, etc. is
such that each subject or part, when the subject is divided
into two or more parts, is complete in itself; hence., in order
to make the index intelligible, it was necessary to give each
subject or part a number. This number is placed at the top
of each page, on the headline, opposite the page number;
and to distinguish it from the page number it is preceded by
the printer's section mark (§). Consequently, a reference
such as § 16, page 26, will be readily found by looking along
the inside edges of the headlines until § 16 is found, and
then through § 16 until page 26 is found.
International Textbook Company
CONTENTS
Cotton Section Page
Cotton Cultivation 14 1
Structure of the Cotton Fiber 14 5
Cottons of the World 14 9
Cotton Used in America 14 12
Tables of Cotton Characteristics .... 14 16
Ginning and Baling 14 16
Marketing Cotton 14 27
Selection and Classification 14 27
Cotton Markets of the United States . . 14 32
Exportation of Cotton 14 34
Pickers
Yarn-Preparation Processes 16 1
Processes Employed for the Production of
Cotton Yarn 16 2.
Cotton Mixing 16 6
Bale Breaker 16 10
Picker Rooms 16 13
Arrangement of Machines 16 14
Feeding and Opening 16 17
Cotton Pickers 17 1
Construction and Operation of the Breaker
Picker 17 5
Intermediate and Finisher Picker .... 17 23
Measuring Motion 17 32
Adjustments 17 34
Gearing 17 37
Care of Pickers 17 39
iii
iv CONTENTS
Cotton Cards Sectioji Page
Card Construction 18 3
The Revolving-Top Flat Card 18 3
Gearing 18 33
Speed Calculations '. . 18 39
Former Methods of Card Construction . , 19 1
Stationary-Top Flat Card 19 2
Roller-and-Clearer Card 19 5
Double Carding 19 8
Card Clothing 19 9
Teeth 19 11
Method of Clothing Cards 19 22
Care of Cards 19 29
Stripping 19 32
Grinding 19 36
Setting 19 56
Management of Room 19 70
Drawing Rolls
Common Rolls 20 1
Top Rolls 20 4
Covering Top Rolls 20 6
Varnishing 20 13
Metallic Rolls 20 15
Setting and Weighting Rolls 20 18
Rules Governing Setting 20 18
Weight-Relieving Motions ....... 20 32
Clearers and Traverse Motions 20 33
Railway Heads and Drawing Frames
Railway Heads 21 1
Principal Parts of the Railway Head ... 21 3
Drawing Frames 21 17
Gearing 21 33
Management of Drawing Frames .... 21 35
Combers
Combing Equipment 22 1
Sliver-Lap Machines 22 3
CONTENTS V
Combers — Contimied Section Page
Ribbon-Lap Machines 22 8
Single-Nip Comber 22 13
Combing Operation by the Half Lap . . 22 22
Piecing-Up Motion 22 25
Combing by the Top Comb 22 34
Delivery of the Stock 22 37
Gearing 22 41
Variations in Construction 22 45
Double-Nip Comber . . , 22 47
Setting and Timing 23 1
Setting 23 2
Timing .'23 17
.Management of the Comber Room ... 23 25
Fly Frames
General Construction of Fly Frames ... 24 1
The Slubber 24 4
Passage of the Stock 24 4
Method of Inserting Twist 24 16
Winding the Roving on the Bobbin ... 24 17
Gearing 24 24
Dimensions of Fly Frames 24 27
Principal Motions of Fly Frames .... 25 1
The Combs 25 13
Builder Motions 25 14
American Type of Builder 25 16
English Type of Builder 25 20
Methods of Driving Bobbin Shafts ... 25 22
Stop-Motions 25 26
Creel 25 28
Management of Fly Frames 26 1
Starting Fly Frames 26 9
Care of Fly Frames 26 15
Common Defects 26 21
Sizing 26 23
COTTON
COTTON CULTIVATION
INTRODUCTION
1. Principal Species. — Cotton is a vegetable fiber —
the fruit of a plant belonging to the order of the Malvaceae,
to which belong the mallow, the hollyhock, and the okra.
The cotton plant belongs to the genus Gossypiiini, and the
number of species from a botanical point of view is variously
stated as from four to eighty-eight, according to different
botanists. The principal species of the cotton plant cultivated
for commercial purposes are: Gossypiiim herbaceian, Gossypiiim
arboreum, Gossypiuvi hirsutum, and Gossyphun Barbadense.
The species known as Gossypiiim lierbaceuin grows
from 2 to 6 feet high and is found native or exotic in
Northern Africa and in Asia; it is also largely cultivated in
the United States of America.
The Gossypiiini arboreuni grows to the height of 15 or
20 feet, whence it derives the name of tree cotton. The
seeds are covered with a short green fiber. While the plant
is found in Asia, it is most largely cultivated in Central and
South America.
The Gossypiiini liirsiitiini is a shrubby plant, its maxi-
mum height being about 6 feet. The young pods are hairy;
the seeds numerous, free, and covered with firmly adhering
green down under the long white wool.
The Gossypiuni Barbadense attains a height of from
5 to 10 feet. The seeds of this plant are black and smooth
and the fiber the longest known to commerce. The name is
Far notice of copyright, see page immediately following the title page
HI
2 COTTON § 14
derived from the fact that the plant is a native of the Barbados,
or has been cultivated there for a long time. The sea-island
cotton plant of the United States belongs to this species.
Cotton fiber is known to commerce under the simple name of
cotton in English-speaking countries, although by some people
it is spoken of as cotton wool. Its German name is baum-wolle;
in French, its name is coton; in Spanish, it is called algodoii.
2. Growth aud Development. — In cultivating cotton
in the United States, the time of planting the seed varies
according to the latitude of the district in question, but
occurs in April in the majority of districts. In some of the
favored districts of Mississippi, Louisiana, and Texas, where
the season is abnormally long, the seed is planted in the latter
part of March. In the heart of the cotton belt, April 1 is
accepted as a suitable date; in North and South Carolina and
Tennessee it is considered unwise to plant before April 15;
while in the extreme northern edge of the belt, as in Virginia,
planting is deferred to the last days of April or early in May.
Germination occurs rapidly after the sowing of the seed,
the first appearance of the plant above the ground being
from 4 to 14 days after sowing. From the germination
period until the middle of the summer the stalk and foliage
of the plant are developed until the plant attains its max-
imum size; during this period hot, humid weather with fre-
quent showers is favorable. From the middle of summer
and onwards the bearing season of the plant occurs, when
more heat and less moisture are desirable.
Usually about 40 days after the plant shows above the
ground there appears the first square, or bud. From the
formation of this bud 24 to 30 days elapse before the appear-
ance of the flower. The flower on the first day of the open-
ing of the bud is yellowish white and has five petals. One
peculiarity of the cotton plant is in the change of color of
the flower. This, which on the first day is of a shade vary-
ing from a dull white to a yellow, is found on the second day
to be of a distinctly pink or reddish hue; the flower drops off
on the succeeding, or third, day.
§ 14 COTTON 3
After the petals fall, there remains the small boll envel-
oped in the calyx; this develops until it becomes about the
shape and size of an egg, and finally bursts from 50 to 60 days
after the appearance of the flower.
When the boll bursts, it exposes from three to five cells
divided by membranous walls; each cell contains seeds,
Pig. 1
which are attached by filaments to the membrane of the boll.
The filaments ultimately disappear, leaving the seed loose
in the cavity and covered with cotton. Each seed is entirely
enveloped by the cotton fibers attached to it just as the
COTTON
§14
human hair is attached to the head. The seeds vary in number
from thirty-two to thirty-six in each pod, or boll. The view
at a, Fig. 1, shows an empty pod, or capsule; b is the seed
cotton out of one cavity of the pod just as it appears after it
has been removed by
the fingers of the cot-
ton picker; c shows
the individual seeds
and fibers of which
the mass b is com-
posed. The next
view, Fig. 2, is a
reproduction of sec-
tions of these seeds
with the fibers radi-
ating in all directions,
each attached at one
end to the seed. Bot-
anists differ as to the
exact cause of the
bursting of the boll,
but it is probably due to the increased space occupied by the
fiber as it ripens and dries and the contraction and splitting
of the pod from the same cause.
Fig. 2
3. The operations of cotton culture on land that has been
previously cultivated, and on well-managed farms, may be
summarized as follows, varying according to the latitude of
the cotton field: Breaking up, burying vegetation, broadcast
manuring, and harrowing, December and January; bedding
up, February; fertilizing, March; sowing seeds, April; chop-
ping out to a stand and throwing soil up to the root. May;
(considerably more seeds are sown than plants required;
the excess of plants are chopped out with hoes); cultivating
by plow and hoe, or cultivator, latter part of May or in June;
period of rest, part of July and part of August; picking,
August, September, October, November, and if the season
is an open one, December and even January.
§14
COTTON
STRUCTURE OF THE COTTON FIBER
4. The cotton fiber, which to the naked eye appears to be
a fine, smooth, and solid filament, exhibits a somewhat com-
plicated structure when examined under a microscope. A
microscopic view of cotton fibers is shown in Fig. 3. Each
fiber appears to be a collapsed tube with corded edges, twisted
many times throughout its
length and having the ap-
pearance of an elongated
corkscrew. This semi-
spiral construction assists
in the formation of a strong
thread from such a com-
paratively weak fiber as
cotton. In the formation
of a thread, the convolu-
tions interlock with one
another and help to resist
any tension put on the
yarn. These convolutions ^'°- ^
are less and less frequent as the fiber is less matured, and
are almost altogether absent in the immature fiber, which
has merely the appearance of a flattened ribbon when exam-
ined under a microscope. The immature fiber is transparent
and has a glossy appearance, so that when it exists in any
quantity in a bale of cotton it can readily be detected with
the naked eye. It has the feature of not taking dye so
readily as ripened cotton.
If examined under a more powerful microscope, the cotton
fiber is found to consist of four distinct membranes, or layers
of matter. Ignoring the removable foreign matter contained
in raw cotton, such as sand and other mineral substances,
leaf, pieces of boll, or stalk, and considering the fiber as
being entirely cleared from this, it is found to be composed
of cellulose, permeated by a small amount of mineral mat-
ter, and that each fiber is surrounded by soluble substances
present to the extent of from 1 to 2 per cent. The small
6 COTTON § 14
amount of mineral matter may be liberated by burning the
fiber, the inorganic matter remaining as an ash retaining
more or less the formation of the fiber and being about
1 per cent, of the original weight.
Cellulose is the largest constituent of the cotton fiber; in
fact, it is the chief constituent of almost everything of veg-
etable origin, but is found with its most characteristic
features in such commercial fibers as cotton, ramie, flax,
and so on. It is a carbohydrate, so called because it is
composed of carbon, hydrogen, and oxygen, the hydrogen
and oxygen being present in the same proportion as in
water. It is this cellulose that absorbs and retains moisture,
the cellulose in the cotton fiber, when in an air-dry condition,
containing about Ti per cent.
The soluble substances present in the cotton fiber, princi-
pally located on the outside, are waxy or oily substances
permeated with other material and amounting in the aggre-
gate to from I2 to 2 per cent, of the weight of raw cotton.
The nature of these materials is, as yet, more or less
obscure; the portion that is removable by scouring with a
weak solution of soda ash is commonly spoken of as cotton
wax, while others removable by prolonged boiling in dis-
tilled water are given the name of zvaier extract.
5. The amount of removable foreign matter in cotton
varies greatly with the variety, and even in diliferent growths
of the same variety. It is present to the extent of from 1 per
cent, in carefully cultivated sea-island to 6 per cent, or more
in coarse, negligently cultivated East Indian cotton. Assum-
ing 2 per cent, as a fair average, the following data repre-
sent the constituent parts of what is commercially known
as raw cotton: Cellulose, 87 per cent.; waxy, or other easily
soluble substances, 2 per cent.; ash, 1 per cent, (giving
90 per cent, of fiber if absolutely dry); removable foreign
matter, 2 per cent.; moisture, 8 per cent. Of course no two
analyses give the same result and these figures only repre-
sent what would be found in an average of American-grown
cotton in an air-drv condition.
§ i-k COTTON 7
6. The property of containing and retaining moisture,
even when in an air-dry condition, or hygroscopicity , is com-
mon to most of the commercial textile fibers, although cotton
possesses this property to a smaller extent than most other
fibrous materials. There is a quantity of water always
present in cotton that cannot be driven out by a moderate
heat, and which, even after it has been expelled by excessive
heat, is replaced by moisture from the atmosphere when the
superheated cotton is allowed to stand in the open air.
When in an air-dry state, under ordinary atmospheric con-
ditions, cotton contains about 8 per cent, of moisture.
The expression air d>y is used to describe the condition
of cotton after it has been exposed to the atmosphere for
such a length of time and under such conditions as will
cause it to lose all excessive moisture or regain deficient
moisture, so as to be in a normal condition. The expres-
sion absolutely dry cotton means cotton that has been heated
to such a high temperature and under such conditions that
all the moisture has been expelled and the sample being
tested will cease to lose weight.
Moisture is necessary to the satisfactory manipulation of
the fiber in spinning, and if for any reason a portion of this
natural moisture is driven out, the spinning of the yarn
is rendered more difficult until it is replaced. Frequently,
from 1 to la" per cent, of excessive or artificial moisture
is found in cotton beyond the amount named. The amount
of moisture in raw cotton depends largely on the treatment
of cotton after picking and before baling, on the age of the
cotton, and where it has been stored. The largest amount
of natural moisture in cotton is found immediately after it
has been picked from the cotton plant, especially in the case
of cotton picked early in the season. In some districts,
especially in the sea islands, it is customary to spread the
newly picked cotton in the sun, to ripen and dry it, before
ginning; but in the main cotton belt no such care is taken,
the result being that the cotton is ginned while moist, tend-
ing to gin damage; but the planter ignores this in his anxiety
to have it baled with as little loss of weight as possible.
^ COTTON §14
The determination of the amount of moisture present
is commonh^ spoken of as conditioning. The accurate mean-
ing of this expression is the testing- of raw stock, yarn, or
fabrics as to what should be their true weight if the normal
regain of moisture were added to their absolutely dry
weight. From this expression, the name conditioning houses
has been derived to indicate those establishments, very com-
mon in Europe, where fibrous substances are tested as to their
hygroscopic conditions. At all these, the standard of moisture
in cotton is what is known as an '^\-per-cent. regain. This
does not mean that every 100 pounds, or other units of weight
of cotton, when in an air-dry condition contains 8i units of
water; the meaning of the term is that if a sample of cotton
has been subjected to sufficient heat to render it absolutely
dry, each 100 parts by weight when exposed to ordinary
atmospheric conditions will regain 8^ parts. Thus, in an
absolutely dry condition, such a sample of cotton would contain
7.834 per cent, of water, which is the relation of 82" to IO82.
7. Measurements of the Cotton Fiber. — Cotton fibers
even from the same seed vary considerably in length and
in diameter, and only approximate measurements can be
given. The diameter of a cotton fiber varies from .0004 to
.001 inch, and the length of the fiber from \ inch to 2i inches.
Doctor Bowman is the authority for stating that there are
140,000,000 fibers in a pound. The general average measure-
ments for cottons of the United States are given in the
United States Government Tenth Census Reports as follows:
Length, 1.10 inches (27.89 millimeters); diameter, .00091 inch
(.023 millimeter); strength, 125.6 grains (8.14 grams).
The strength of individual cotton fibers varies from 75 to
300 grains, according to the kind of cotton, the distance
between the points of suspension in making the test, and the
portion of the fiber selected for the test. Usually the long-
stapled, fine cottons break with the least strain, and the short
coarse cottons stand the greatest strain. The ordinary
American cottons have a breaking strain of from 120 to
140 grains.
§ 14 COTTON 9
8. Testing Yarns and Fabrics Containing? Cotton.
It is sometimes necessary to determine whether or not a
fabric or a yarn is made of cotton, and while the experienced
maniifacturer is usually able to detect this by the appearance
of the fabric, there are several tests that can be applied. In
the first place, a microscope is useful, as the appearance of
the cotton fiber when highly magnified is different from that
of silk, linen, or wool, the wool fiber being covered with
overlapping scales, silk being smooth like a glass rod,
and linen showing the vascular fiber bundles that make up
the complete fiber. In addition to the microscopical test,
another may be made b}^ burning a small portion of the yarn
or fabric. Cotton will be found to burn with a flash, leaving
a very light ash, while animal fibers, such as silk and wool,
burn more slowly, emitting an offensive odor and leaving a
curled bead, or globule, of carbonized matter. Chemical
tests may also be made b}^ which the nature of the fiber may
be determined without anv doubt.
COTTONS OF THE WOKLD
9. Quantity and Quality Produced. — While the cotton
crop of the United States is the most important and most
useful in the world — being of such importance, in fact, that
the price of American cotton practically controls the price of
other cottons — there are numerous cotton fields in various
parts of the world where extensive crops are raised and the
product used for purposes for which American cotton cannot
be utilized. The most important cotton-growing countries,
other than the United States, are India, Egypt, China, and
Brazil. Fig. 4 shows the proportion of cotton raised in sev-
eral countries to the world's crop in 1900-1901.
Sea-island cotton of the United States represents the
highest quality, and is spun into the finest yarn, being used
very largely for thread, laces, and fine cambrics. Next in
fineness of quality and length of staple is the brown Egyp-
tian cotton, so called because of its brownish tinge, which
is a distinctive feature of this fiber; this is very largely used
10 COTTON §14
tor fine cotton yarns and goods of all varieties. Among
other long-staple cottons that are not important commercially
are the Tahiti sea-island, the Peruvian, the white Egyptian,
and Egyptian Gallini cottons. The next grade of cotton of
any importance is known as Brazilian; it has a staple rather
longer than the average American cotton, but is some-
what rough in appearance and touch. The American cottons
form the next class, as regards quality, varying from the
fine Mississippi cottons. Peelers, and benders, to the short,
clean uplands cotton.
World's Crop 15,127,000 Bales of 500 Pounds
United States of America 10,546,000
India 1,981,000
China and Corea 1,100,000
Egypt 1,075,000
■
South America 225,000
■
Other Crops 200,000
Fig. 4
Next to the United States, China produces one of the
largest crops of cotton, which is almost all consumed in
that country. It is a beautiful white cotton, somewhat
harsh to the touch, but, unfortunately for its commercial
importance, is comparatively short-staple, being about the
length of the shortest American uplands cotton. The East
India crop is also large, but is regarded as being both the
dirtiest and the shortest-staple cotton produced.
10. Productive Regions. — Owing to the long seasons
of considerable heat required in order to bring cotton to
§14
COTTON
11
maturity, this fiber can only be profitably cultivated in
certain regions bordering north and south of the equator.
This is usually described as being the regions bounded by
the lines of latitude 45° north and 35° south of the equator,
but no such arbitrary divisions can be made, as the isother-
mal lines must be taken into account. For instance, a line
Fig. 5
drawn along 45° north latitude includes such districts as New
England and portions of Canada, where it is impossible to
grow cotton under natural conditions, while if the lines were
drawn about 38° north latitude, Avhich is the northern limit of
cotton-growing districts in the United States, it would exclude
portions of Turkestan, Southern Italy. Greece, and other
12 COTTON § 14
districts where it is possible to cultivate the cotton plant
with success. Thus, an isotherm must be followed along^
the lines of equal temperature in the northern hemisphere,
and another isothermal line in the southern hemisphere.
This practically embraces in North America all the southern
portion of the United States, including all of Georgia, South
Carolina, Alabama, Mississippi, Texas, Louisiana, and
Arkansas, and parts of Virginia, North Carolina, Tennessee,
Indian Territory, California, and Florida; Mexico and
Central America; and in South America, Peru, the Argentine
Republic, Brazil, Venezuela, and Guiana. In Europe, the
islands of Malta, Sicily, southern portions of Spain and
Italy, and parts of Greece and Turkey are included, while
the Asiatic countries are Arabia, Persia, Turkestan, India,
China, Japan, and some of the islands in the Malay Archi-
pelago. In Africa, a very large region is suited to the
cultivation of cotton, but at present it is cultivated only in
Egypt, in some of the countries on the western coast, and to
a small extent in South Africa. In Australasia, it can be
cultivated in Queensland and the Fiji Islands.
Fig. 5 shows the relative length of staples of the following
leading growths: (a) American sea-island, (d) Peruvian,
(c) Brazilian, (d) brown Egyptian, {e) American, (/) Indian,
ig-) Chinese, {h) Japanese.
Tables I, II, III, and IV show the relative importance,
according to the quality, of cottons raised in various countries.
COTTON USED IN AMERICA
SEA-ISLAND COTTON
11. Sea-island cotton is the name used commercially
to indicate the United States sea-island cotton. This is
grown on Edisto, St. Helena, Port Royal, James, and John
islands off the coast of South Carolina, St. Simon and
Cumberland islands oflf the coast of Georgia, and others.
It is recognized as being the best cotton that is grown in any
§14 COTTON 13
part of the world. Very careful attention is given to its
cultivation and ginning, quality being considered before
quantity, and thus sea-island cotton has a long, fine, strong
and silky fiber with comparatively regular convolutions, of
a diameter from .0004 to .0006 inch, ranging in length from
1 1 to 21 inches. The sea-island cotton crop is about 93,000
bales per annum; Charleston, South Carolina, is the leading
market for it.
Sea-island cotton is largely used for thread and lace-making
purposes, and is regularly spun into from 150s to 400s yarn,
and occasionally, even for commercial purposes, as high
as 600s. It is said that 2,150s yarn was spun from sea-island
cotton at the exhibition of London in 1851. Where great
strength is required for heavy goods, sea-island cotton is
sometimes used, even for coarse yarns; as, for example, the
linings of bicycle tires, sail cloth, and so on.
The variety of so-called Florida sea-island cotton is grown
on the mainland of Florida from sea-island seed; this is
somewhat inferior to the sea-island proper, but is a very
useful cotton for making yarns of a little better quality than
those made from Egyptian cotton. It has a white, gloss3%
strong fiber, a little coarser than the strictly sea-island, and
is not quite so carefully cultivated. It is suitable for yarns
from 150s to 200s.
AMERICAN COTTON
12. While the sea-island cottons just described are
American, this name is seldom applied to them, but is used
to indicate the typical cotton of the world, which is grown in
the Southern States of the United States and used wher-
ever cotton-spinning mills exist. The cotton described
commercially as American is suited to medium numbers
of yarn; is usually clean, fairly regular in length of staple,
satisfactorily graded, and consequently is one of the most
reliable and useful cottons for a manufacturer's use. The
quantity is greater than that produced in all other parts
of the world together, and consequently the price of
American cotton in Liverpool, which is the greatest market
14 COTTON § 14
for it, greatly influences the price of cotton throughout the
world.
American cotton may be divided into three important
classes; namely, gtdf cotton; upla7ids, or boweds; and Texas
cotton.
13. Gulf, or New Orleans, cotton usually consists
of cotton raised in the basin of the Mississippi River, inclu-
ding the states of Louisiana, Mississippi, parts of Arkansas,
and Alabama. The name gulf cotton is generally used in
America and originates from the fact that most of this cotton
is shipped from states bordering on the Gulf of Mexico. In
Europe, the name New Orleans is usually applied, and is
derived from the shipping port of that name. Gulf cotton is
from 1 inch to li inches in length of staple, from .0004 to
.0007 inch in diameter, and is generally used for yarn from
28s to 44s warp and from 50s to 70s filling or ply. This
style of cotton may be subdivided into others, known as
Memphis, benders, Allan-seed, Peelers, and so on. These
names were originally intended to represent certain kinds of
cotton, but have been very much misapplied of late years.
The benders, or bottom-land, cotton is supposed to be grown
at the bends of the Mississippi River, which are occasionally
flooded and consequently well fertilized by the silt of the
river. It is one of the better grades of gulf cotton, and
is used for the higher numbers named above. The best
qualities of gulf cotton are known as Allan-seed and Peelers.
These are used for fine yarns, often for fine combed yarns,
and by some spinners are preferred to Egyptian. The color
is bluish-white rather than cream-colored, and somewhat
resembles short Florida sea-island.
14. Uplands cotton is grown in the undulating country
between the ocean and the mountains in the states of
Georgia, North and South Carolina, Virginia, and Alabama.
It is generally used for filling yarns below 40s, although it
may be spun higher if required. The length of the staple is
from f to 1 inch and the fiber is from .0006 to .0007 inch in
diameter. This cotton is usually very clean.
§ 14 COTTON 15
15. The cultivation of Texas cotton is largely on the
increase, and for coarse warp yarn it is the most suitable
cotton. In dry seasons, it is apt to be somewhat harsh and
brittle and cannot be relied on as much as gulf or uplands
cotton. The staple is usually from « to 1 inch in length
(sometimes exceeding this), and from .0005 to .0007 inch in
diameter. Up to 26s and 32s warp yarns and 32s and 40s
filling yarns are often made from Texas cotton, although it
is eminently useful for warp. Indian Territory and Okla-
homa cottons are of the Texas style.
Local circumstances often affect the use of cotton in the
Southern States. A North Carolina mill may use an uplands
cotton both for warp and filling, because of its being grown
in the vicinity of the mill, although it is really a filling
cotton; while a Mississippi mill may use local cotton for
both warp and filling, although it is really too good for the
latter, and so on.
BROWN EGYPTIAN COTTON
16. The cotton used in American mills is almost entirely
grown in the United States, but in the fine-spinning districts
a quantity of bro%vn Egyptian cotton is used, and in the
woolen mills some long, rough-stapled cotton, such as rough
Peruvian, is in demand. The brown Egyptian cotton is
generally used for warp yarns from 50s upwards, and
filling yarns from 60s upwards intended for use in fine-
woven cotton goods. Some of this cotton is also used for
hosiery yarns and for the manufacture of Balbriggan under-
wear; in this case it is spun into lower numbers than those
just mentioned.
Almost all the Egyptian cotton used in the United States
is combed. The features of brown Egyptian cotton are the
length of staple and fineness of the fiber, it being very silky
and delicate in structure. The Egyptian cotton now grown
is almost entirely of the so-called brown Egyptian type,
being of a very light brown color.
16 COTTON § 14
TABLES OF COTTON CHARACTERISTICS
17. Four tables are printed herewith that have been
gradually compiled during the last 20 years; they are the
result of exhaustive observation and investigation. They
give all the known cottons under their trade names and
state where the cotton is grown, the length of the staple,
the diameter in 10,000ths of an inch, the characteristics and
appearance of the cotton, the numbers of yarn into which it
is usually spun, and whether these yarns are for warp
(twist), filling (weft), or ply yarns (doubling), with other
information.
These tables are intended to indicate the numbers of yarns
usually spun for commercial purposes. For special yarns
that must be strong or of a high grade, the cotton may be
used for lower numbers; or for special or local reasons, it
may possibly be spun into higher numbers, or into warp,
filling, or ply yarn, where not so specified, but these
are unusual cases, and are not considered in formulating
the tables.
The cottons are divided into four kinds: long-stapled,
medium- to long-stapled, medium-stapled, and short-stapled.
GINNING AND BALING
18. Art. 3 gave a summary of the processes necessary
for the cultivation of cotton, including cotton picking; but
after it is picked, and before shipment to the mill, it must be
ginned and baled. Seed cotton as it is picked contains about
two-thirds of its weight in seeds; that is, out of 3 pounds of
seed cotton, only about 1 pound is fiber.
THE SA^V GIX
19. The gin commonly used in America for removing the
fiber from the seed, except in the case of sea-island cotton,
is the one known as the saw gin. Its construction may be
briefly described as a series of revolving circular saws with
§14
COTTON
17
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§14
COTTON
19
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American seed
Some very weak and high
color
Very little grown or used
Resembles the cotton
from (iuiana
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Where (irown
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20
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COTTON
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COTTON
23
fine teeth, so placed that an arc of their circumference pro-
jects through a grid into a receptacle containing the seed
cotton. The lint is torn from the seed and carried through
the grid by the saws, from which it is removed by a brush
and carried to a condenser.
Fig. 6 is a section through a gin, one of the saws being
marked d. The seed-cotton receptacle, or seed box, is
marked a; r is the saw cylinder on which the saws are fixed;
e shows the grate through which the saws project, known as
Fig. 6
the breast, or grate fall. The chamber a is full of seed and
seed cotton. The seed cotton is on the outside of a core of
seed and is thus brought within the operation of the saws.
The seed cotton, having been fed into the chamber a,
passes around on the outside of the mass of seed. The
teeth of the saws, projecting through the grid about 2 or
4 inch, tear the fibers from the seeds nearest to them. The
quick speed of the saws (about 350 revolutions per minute)
sets up a rolling motion of the mass of seed, for which
24 COTTON § 14
reason the chamber a is sometimes called the roll box. New
seed cotton is continually being brought under the action of
the saws, being fed in at p, while the seed when freed
from its fiber drops, at q, to the floor. The fibers are car-
ried forwards by the revolution of the saws and are removed
by a rotary brush.
The circular brush, shown at /, Fig. 6, is an important
part of the machine; it should be filled with heavy bristles
and the framework and ribs should be strongly constructed
and well bound together. The brush makes four or five
times as many revolutions per minute as the saws, in the
direction indicated by the arrow below it, Fig. 6, and the
cotton is either blown into a lint room, on the old system,
or, where a condenser is used, the fibers are drawn forwards
by the air-current to the surface of wire-covered drums or
screens; by passing between these screens they are delivered
in the form of a sheet, being deposited on the floor in the
case of gins that are not connected to a conveyer.
The gins most frequently used have from sixty to eighty
saws, which are either 10 or 12 inches in diameter. The
highest speed that 12-inch saw cylinders should be driven
for good work is 300 revolutions per minute, although they
are frequently detrimentally run up to 400 revolutions per
minute and above. A suitable production for a 60-saw gin
is one bale of 500 pounds per hour.
THE ROLLER GIN
20. A type of gin used both for long- and short-stapled
cotton in many parts of the world — as exemplified by its
almost exclusive use in Egypt, where long-stapled cotton is
grown, and in India, where the cotton is almost all short-
stapled — is the roller gin. There is not much doubt that
the roller gin separates the fiber from the seed with a very
much easier action than the saw gin, but it has not been
adopted in the United States to so large an extent as it
should, being used principally in the sea-island districts, and
even there only to a limited extent. The reason for this is
§ 14 COTTON 25
that the production of the machine is not so great as that
of the saw gin.
There are at least two distinct types of construction of
roller gins in general use, but both of them depend on the
same principle for the removal of the fiber from the seed,
which is to draw the fiber between a rapidly revolving roll
and a sharp knife edge resting against this roll, so that the
fibers are cut ofT near the point of attachment to the seed.
The usual method is to place the seed cotton on a table
or hopper, from which it is gradually fed into a seed box
and presented to a roll covered with heavy hide that
has a roughened surface. A stout knife extends across the
machine near the revolving roll, its edge being parallel
with the shaft on which the roll is mounted. The fine
fibers adhere to the leather covering of the roll, and are
drawn between it and the knife until the seed is pulled
against the edge, when the fibers are severed from it. The
same seed is continually drawn against this knife edge by
different fibers attached to its surface, until it is entirely
stripped, when it falls down and another seed takes its place.
The cotton is being constantly removed from the surface of
the leather roll.
In order to agitate the seeds and aid in the removal of
the fibers as they pass between the knife and the roll, two
methods are adopted, and this difference of construction
characterizes the leading types of roller gins.
21. In what is known as the knife-roller gin, a roll
with Y-shaped or angularly set knives is rotated in front of the
leather roll, and on account of the angle at which the knives
are set, pushes the seeds from side to side and agitates them
sufficiently to aid in stripping the fibers from them by
presenting new surfaces of each to the stripping knife, until
it is absolutely stripped of fiber.
22. In another type of gin, known as the Macartliy
gin, a vertical knife mounted on a connecting-rod attached
to a crank is given a reciprocating motion, and thus effects
the same object. In what is known as the double Macarthy
26 COTTON §14
gin there are two of these knives operated by a double crank
below the machine.
23. All roller gins require considerable care in opera-
tion, especially with regard to maintaining a true surface on
the leather rolls and an even pressure of the stripping knife
on the roll at all points, as well as a proper adjustment
of the blades of the knife roller in the knife-roller gin, or of
the vertical knives in the Macarthy gin. The Macarthy gin
has a production of about 350 pounds of ginned cotton
in a day of 10 hours from the single gin, or 500 pounds
in a day of 10 hours from the double gin, and absorbs
from 1 to I2 horsepower. The knife-roller gin has a pro-
duction of 800 to 1,000 pounds in a day of 10 hours, and
requires 2a horsepower to drive it.
BALING
24. After ginning, the cotton is baled. This is done by
enclosing it in a baling press with an outside wrapper of
coarse burlap, in which it is pressed into comparatively
small compass and held by iron ties.
The bales as they come from the farms or the cotton gins
are too large for economical shipment either by railroad or
steamship. Consequently, at every inland city and seaport
in each cotton state there are compresses. These are power-
ful steam baling presses, in which the cotton bale can be
reduced to smaller dimensions.
Previous to compressing, the exporters affix a tag to each
bale by which to identify it, and take from each bale a sam-
ple, which is numbered the same as the tag. The samples
are then graded and assorted into lots of low middling, mid-
dling, good middling, and so on, as will be explained, and
then shipped (usually in lots of 100 bales) either to Northern
mills or to Europe.
§ 14 COTTON 27
MARKETING COTTON
SELECTION AND CLASSIFICATION
25. The selection of cotton from samples, or the judging
of cotton, is a matter of considerable importance. In order
to become thoroughly proficient, a long- period of practice is
required to produce the trained eye and hand necessary to
distinguish the gradations and differences in quality that add
to, or detract from, the market value of the fiber. This is
not of so much importance in the Southern markets, where
the bales are usually on hand to be referred to in case of
dispute, but in the Northern states, and in any country where
cotton is largely purchased from samples, it is of the utmost
importance.
26. Samples. — Cotton is seldom, if ever, purchased
from the examination of the bale, but from parcels containing
small pieces of cotton from each bale, technically known as
papers of samples. It is customary in well-managed mills
to take samples of each new lot of cotton that arrives at the
mill, sometimes a sample from every bale, and at other mills
only from a certain number of bales out of each hundred.
The samples are then compared with the buying samples to
see if the cotton is equal to the quality purchased.
27. Points to Be Considei*ecl in Judffins Cotton.
In judging cotton from a sample, or in selecting cotton from
a sample with a view to purchasing it, the first thing to do is
to investigate the authenticity of the sample. The points
then determined are: (1) the grade of the sample, (2) the
staple, (3) the color, (-4) the amount of sand, (5) the amount
of dampness, (6) whether the cotton is even running or not.
These points are arranged in order of their usual importance.
This is not necessarily accurate enough for some purposes;
28 COTTON § 14
for instance, in cotton to be used for filling yarns, the color
is more important than in cotton for warp j^arns. As the
warp yarn has to be sized, the appearance of a good-colored
cotton is somewhat spoiled, while on the other hand defects
of a dull-colored cotton are hidden. In either case, the
length of staple may be the most important point to con-
sider where it is desired to produce a strong yarn without
regard to its appearance.
28. Grade. — American cotton is usually graded accord-
ing to a standard agreed on in all the leading cotton markets
of the world, the highest grade being {air, followed by six
other grades, the lowest being ordinary; cotton of lower
grade is called inferior. The seven full grades of American
cotton are fair, middli^ig fair, good middling, middling, low
middling, good ordinary, and ordifiary.
This gradation is not sufficiently fine for the cotton
merchant, and consequently each grade is subdivided into
what are known as half grades and quarter grades. By this
means a list is made up giving twenty-six different grades of
cotton. This list is as follows:
Fair, barely fair, strict middling fair, fully mid-
dling fair.
Middling fair, barely middling fair, strict good
middling, fully good middling.
Good middling, barely good middling, strict
middling, fully middling.
Middling, barely middling, strict low middling,
fully low middling.
IjO'w middling, barely low middling, strict
good ordinary, fully good ordinary.
Good ordinary, barely good ordinary, strict
ordinary.
Ordinary, low ordinary, inferior.
Those terms having the word strict are the half grades,
while those having the words barely and hilly are the quarter
grades. The full grades are printed in bold-face type.
Grade really means the appearance of the cotton as
§ 14 COTTON 29
regards cleanliness, and the above system of grading
depends on the appearance of the cotton as to its freedom
from leaf and other impurities. Some graders take into
consideration what is known as bloom, or brighiness, of the
cotton, which adds to the grade; also, discoloration, known
as off color, or tinges, which detracts from the grade.
29. Staple. — After determining the grade, the next
thing to do is to find the staple. The word staple usually
means the average length of the bulk of the fibers forming
the bale assessed, and is found by taking a small portion of
cotton in the way hereafter described, preparing a tuft of
fibers from which the very short fibers have been removed,
and then measuring the average length of fibers remaining.
Cotton is spoken of by the length of staple; thus, 1-inch
cotton, li-inch cotton, and so on. There is something more
that is usually implied by the word staple — strength of the
fiber. This is determined by holding one end of the tuft
between the first finger and thumb of each hand and break-
ing it. The word staple may therefore be taken to mean the
average length of the fibers forming the bale, and may also
be understood to include the strength of the fibers; thus, the
expressions lengtJi of staple and strength of staple are obtained.
An expert cotton sampler or buyer will often judge cotton
by simply taking a tuft and giving it one pull, judging it by
the amount of drag or cling that must be overcome in pulling
it apart. He thus tests both the length and strength of the
staple at the same time. This skilfulness comes only with
experience, but is the most rapid method of judging cotton.
30. Sand and Dirt. — After the staple has been deter-
mined, it is necessary to discover the amount of sand and
dirt in the cotton. This is often done by raising the cotton
from the paper that holds it and noticing the amount of sand
remaining on the paper, this sand having fallen out by the
repeated handling of the cotton. It is, perhaps, better
to hold the handful of cotton as high as one's head and
shake it so that the sand, if there is any, can be seen to fall
from it.
30 COTTON § 14
31. Dampness. — Another test is that for dampness.
This can only be detected in the sample paper if the samples
are newly drawn, in which case it can be felt by the hand.
If the samples have been in stock for some time, the water
originally contained in them will have evaporated and cannot
be ascertained unless it has previously been so great as to
cause a slight formation of mildew on the cotton, in which
case it is indicated by the smell.
32. The rich, bright, creamy appearance that cotton has,
especially in the early part of the year, is called the blooin.
This bloom is only found on certain growths of cotton and
adds somewhat to its value, especially where it is to be used
for making weft, or filling, yarn, or where the goods into
which it is to be made are to be sold in their unbleached
or undyed state, technically known in Europe as hi the gray ^
and in some parts of America as brotv7i goods.
Tinges, high color, or off color, should be looked for. These
are caused where the cotton has become tinged while on the
plant, through rain stains, or by having fallen on the ground
and become mixed with some of the red clay of the cotton field.
These bales should be avoided, and in case of purchasing from
a sample containing indications of having come from tinged
bales, an agreement for a reduction in price on the bales
ought to be arranged, or a condition made that these bales be
thrown out before shipment of the quantity purchased.
33. The last point, and one that is important, is to see
that all bales are somewhat alike. Usually a sample paper
is made up of a handful of cotton from each of the lot of
bales; by testing first one sample and then another it is dis-
covered whether the lot of cotton is even running. Occa-
sionally, however, if not graded properly by the cotton factor,
a lot of cotton is found to be mixed; some bales may be higher
grade than others, some may be longer-stapled than others,
and even in the same bale an abnormal variation in length and
strength of staple may be found. Cotton of this kind should
be avoided altogether, as it is almost impossible to make satis-
factory yarn out of cotton mixed in this manner.
§ 14 COTTON 31
34. As has been stated, constant practice is necessary to
become a good judge of cotton. Even experienced cotton
graders and cotton buyers improve year by year in their
judgment of the fiber, until some of them, by a quick glance
or the slightest touch, can determine at once whether the
cotton is suitable for their purposes or not. It is not an
unusual thing for a cotton buyer in a market like Liverpool
to become so expert as to be able to examine in a single
day type samples representing tens of thousands of bales.
Usually the grade is mentally determined; then a small
handful of cotton is grasped by both hands, having the
thumbs uppermost, and pulled apart. One-half is thrown
away, and the ends of the fibers that project from the other
piece are grasped between the thumb and the first finger of
the right hand, and the left hand is employed in removing
short fibers, or hid, from the tuft. The tuft of cotton, now
much lessened in size, is grasped by holding the other ends
of the fibers in the left hand, while the right hand removes
more short fibers, or fud. By these few quick movements
an experienced cotton sampler has arrived at a small tuft of
fibers laid parallel, which can first be measured, usually with
the eye only, and afterwards grasped firmly between the first
finger and the thumb of each hand, the thumbs being upper-
most, and broken by a short, strong pull. By always taking
the same amount of cotton in the hand at once, and redu-
cing it to the same-sized tuft, the cotton sampler fixes a
standard of length and strength for himself, by which he can
assess the value of almost any kind of cotton.
An accurate judgment of the length of staple can only be
acquired by experience and practice, and a uniform method
should be cultivated. By removing all short fibers and
retaining only the longest ones for measurement, too long
a measurement is obtained. This is often done by those
interested in the sale of the cotton. By throwing out the long
fibers and measuring the shortest ones, the length obtained
does not fairly represent the staple of the cotton. A cotton
sampler who wishes to give an impartial judgment will throw
out all the shortest fibers, or the fud and the waste, and also
32 COTTON § 14
the longest fibers, which are evidently unrepresentative of the
bulk of the cotton, leaving a bunch of fibers fairly even in
length and typical of the majority of the fibers in the bale.
These fibers are then measured.
35. After the grade and staple have been determined in
the manner just named, a test is made for sand and for
uneven running; the appearance as to bloom, color, and
evidences of gin damage is then noticed, completing the
test of the cotton, by which time a cotton expert should
have made a mental estimate of its value.
In regard to gin damage, it should be stated that this often
occurs when cotton is ginned on the saw gin while damp; it
is also caused if the gin is operated at too high a speed.
Cotton in this condition can be recognized by being curled
and stringy, with the fiber broken or cut.
Another point to be noted in this connection is that local
circumstances often affect the judgment on a lot of cotton;
for instance, a good north light is the best in which to judge
cotton, as this light is more regular than any other. Cotton
should not be purchased from a sample wrapped in paper
with a blue lining, unless it is removed for examination, as
this causes the cotton to appear better than it really is.
COTTON MARKETS OF THE UNITED STATES
36. The largest crop in any of the states is raised in
Texas, and this makes Houston one of the most important
interior markets of the United States. In the season of
1899-1900, 550,000 bales of cotton were sold in this market,
which amount was excelled only by the gulf port New
Orleans, where 1,002,000 bales were sold in the same season.
Memphis, on the Mississippi River, is a market of importance
and is a great center for long-stapled cotton. In the season
referred to, 477,000 bales were handled at Memphis and
267,000 at Augusta, Georgia.
Among other important cotton markets are Savannah,
Georgia; Charleston, South Carolina; Mobile, Alabama;
St. Louis, Missouri; Shreveport, Louisiana; Vicksburg
§ 14 COTTON 33
and Columbus, Mississippi; Macon, Columbus, and Rome,
Georgia; Selma, Montgomery, and Eufaula, Alabama; and
Nashville, Tennessee.
MILL. PURCHASES OF COTTON
37. The cities of Boston, Providence, New Bedford, and
Fall River are important markets for cotton, as many of the
Southern factors have agents or branch offices at these points.
In the fall, the salesmen of these houses, together with spe-
cial agents who are sent from the cotton belt, are very busy
in ofifering cotton to the manufacturers, who buy large quan-
tities from October until March. The treasurers of the mills
are usually the cotton buyers, and they select cotton from
the samples that have been sent from the cotton factor,- show-
ing the style of cotton that he is offering. Practically the
whole of the cotton required for a year is purchased in the
period named above, and very frequently it is shipped North
immediately after the sale takes place. Arrangements are
occasionally made for the shipment of so many bales per
month.
Money can be borrowed at very much lower rates of
interest in New England than in the South, and consequently
it is much cheaper to carry or hold cotton in the North, as in
most cases the parties hold it on behalf of the banks that
have loaned money to enable them to carry it. For this
reason most of the large cotton-manufacturing establish-
ments of New England have very large storehouses con-
nected with their mill buildings, and the winter is usually
a very busy time in receiving this cotton, and weighing,
sampling, and storing it for future use
The terms on which Northern manufacturers buy cotton are
very simple. Usually the cotton is sold on cash terms, with
no discount being allowed and no allowance being made for
bags or ties, the gross weight being invoiced. The cotton
is usually purchased delivered in Boston or an equivalen.
point, a freight rate allowance being made by the shipper
equal to the amount that the manufacturer pays for the
freight on arrival of the cotton. It will be seen that the
34 COTTON § 14
above system requires that a very large stock of cotton be
kept at the mills for a considerable portion of the year.
While the above system is a general one, there are
special cases in which the cotton is purchased as needed;
in these cases it is not unusual for manufacturers to send
mail orders to reliable Southern houses that know what grade
of cotton they are accustomed to use, specifying the length
of staple, grade, and style of cotton, and leaving it to the
Southern merchant to ship the quality of cotton desired. In
cases of this kind, cotton is said to be bought on descrip-
tion; that is to say, the mill will purchase cotton, simply
stating that it is to be of a certain grade and certain length
of staple; for instance, 100 or 1,000 bales good middling
li inches.
EXPORTATION OF COTTON
38. The exports of cotton and its products from the
United States in the fiscal year ending 1901 exceeded the
export value of any other class of exports, averaging
$1,000,000 per day throughout the year. The actual figures
are as follows:
Cotton, raw $313,673,443
Cotton manufactures . . 2 0,2 7 2,4 1 8
Cottonseed oil 1 6,5 4 1,3 2 1
Cottonseed meal 1 3,1 1 9,9 6 8
Cotton waste 1,4 3 1,6 4
Cottonseed 3 6 6,9 5 3
Total , . . . $3 6 5,4 5,7 7
PICKERS
(PART 1)
YARN-PREPARATION PROCESSES
INTRODUCTION
1. Condition of Stock. — The condition in which the
raw cotton reaches the cotton mill is that of a compressed
bale. In a few sections in the United States and in some
foreign countries where cotton mills are located in close
proximity to the cotton fields, the cotton is delivered to the
mill in a loosely packed bale that has not been compressed,
and in some cases even as loose cotton taken from the cotton
gin to the mill without baling. Instances of this kind are
very rare, however, compared with the general method of
delivering cotton in the form of a compressed bale, which
is the condition that will be accepted as a standard. A com-
pressed bale of cotton is a matted mass of innumerable
fibers lying in all directions, with which are intermixed
sand, broken leaf, sticks, broken seed, and other foreign
matter. The fibers themselves, although approximately of
the same quality, are not, even in the same bale, exactly of
the same length, nor are they all ripened to the same point
of maturity, while some of them may have been cut by the
action of the gin, or rolled into iieps; that is, into small
bunches of closely matted and tangled fibers that have the
appearance of specks in the cotton and, while varying in size,
are generally very minute, rarely being larger than an ordi-
nary pin head.
For notice of copyright, see page immediately following the title page
I 16
2 PICKERS §16
2. Object of Cotton -Yarn Mills. — From this mate-
rial, it is the object of the cotton-yarn mill to produce a
clean, smooth, even thread from which all foreign matter
has been removed, and which consists only of the perfect,
or approximately perfect, fibers, the neps and excessively
short fiber having been thrown out. In order to produce
a comparatively strong thread, the fibers not only must
be cleaned, but must be arranged approximately parallel
to each other and assembled by a system in which a loose
strand or ribbon of fibers is produced, which is gradually
attenuated until it arrives at the correct fineness, when it
is twisted to give it strength, and in that condition is spoken
of in the cotton manufacturing business as yarn. This,
then, in general, is the object of the cotton-yarn mill — to
produce from the bale of raw cotton as large a percentage
as possible of cotton yarn, which should be smooth, clean,
even, and strong.
One pound of cotton must be spun into yarn of which
there is seldom less than 1 mile to a pound, usually 10 miles
or even a greater length than this; and in some cases, for
special purposes, there may be 100 miles or more. The
problem is not only a mechanical one, but one involving
a constant study of economy and also aiming at an excel-
lence of production as far as is consistent with the proper
economical operation of the yarn mill.
PROCESSES EMPIjOYED FOR PRODUCTION
OF COTTON YARN
3. In order to produce cotton yarn, the fiber is passed
through a number of processes, varying from ten in a mill
manufacturing coarse yarns to fifteen in one making fine
yarns. These processes may be divided into three classes,
as follows: (1) mixing; (2) cleaning; (3) parallelizing and
attenuating. In this classification, those processes that
follow the spinning are of course ignored, although in a
mill making yarn for sale, a fourth class might be made of
processes for preparing the yarn for the market.
§16 PICKERS 3
4. Yarn is spoken of as being coarse, medium, or fine,
according to the thickness of the thread, and this in turn is
determined by the number of hanks to the pound. A hank
of cotton yarn contains 840 yards, and the size of the yarn is
indicated by the number of these hanks required to weigh
1 pound; thus, 10s yarn would contain 10 hanks, or 10 X 840
yards, making 8,400 yards, in a pound; 40s yarn would con-
tain 40 hanks, or 33,600 yards, in a pound. The higher the
numbers, that is, the greater the number of hanks in a
pound, the finer is the yarn.
No arbitrary rule can be given for determining which is
coarse yarn, which is medium, or which is fine, as a manu-
facturer accustomed to making only coarse yarn might
consider 30s fine, while another manufacturer engaged princi-
pally in the use of fine yarns would consider 30s coarse. A
general classification would be to consider yarns below 30s
as coarse; from 30s to 60s as medium numbers; and above
60s as fine yarns. The expression lozv munbcrs is sometimes
applied to coarse yarns, and high njir,diers, to fine yarns.
The number of a given yarn is commonly spoken of
as its counts; thus, it is said that the counts of yarns
are 10s, 12s, 36s, etc.
5. The processes adopted in different mills vary accord-
ing to whether the mills are intended for coarse, medium,
or fine yarns. A mill making medium yarns, for instance about
32s, would in most cases use the following machines: auto-
matic feeder, opener, breaker picker, intermediate picker,
finisher picker, card, first drawing, second drawing, third
drawing, slubber, intermediate, roving frame, spinning frame.
In cases where the railway head is used, it comes between
the card and the first drawing; in this case the third draw-
ing is omitted. Where the bale breaker, or cotton puller, is
used, it takes a position before the automatic feeder. Where
the mule is used, it takes the place of the spinning frame.
For coarser numbers, the above list is changed by omitting
one or more of the parallelizing and attenuating processes,
and sometimes adding a cleaning process. In changing the
4 PICKERS § 16
list to suit finer yarns, the reverse is the case; one clean-
ing process, or more, is omitted and attenuating processes
are added, but for very fine yarns, a cleaning process,
namely, combing, is added.
Below will be found combinations of machinery suitable
for mills making various numbers.
6. The machinery for yarn mills making 10s and below
is as follows: automatic feeder, opener, breaker picker,
intermediate picker, finisher picker, card, first drawing,
second drawing, slubber, roving frame, spinning frame. The
railway head may be used instead of the first drawing process.
The machinery used in yarn mills making about 100s is as
follows: automatic feeder, opener, breaker picker, finisher
picker, card, sliver-lap machine, ribbon-lap machine, comber,
first drawing, second drawing, third drawing, fourth drawing
(optional), slubber, first intermediate, second intermediate,
roving frame, mule. Sometimes a drawing process is used
between the card and the sliver-lap machine. Where four
processes of drawing are used, the roving frame is not
necessary, and where four processes of fly frames (slubber,
first intermediate, second intermediate, and roving frame)
are used, it is not always necessary to have more than three
processes of drawing.
The machinery used in yarn mills for making 200s is as
follows: automatic feeder, opener, breaker picker, card,
sliver-lap machine, ribbon-lap machine, comber, first draw-
ing, second drawing, third drawing, fourth drawing, slubber,
first intermediate, second intermediate, roving frame, mule.
The names given to the fly frames vary in different sec-
tions, and in some places they are known as slubber, inter-
mediate, roving frame, and jack frame.
7. What are known as do2ible-cnrdiiis; processes were for-
merly very often employed, but are now going out of use
both for coarse and fine yarns. Any of the preceding com-
binations can be converted into double-carding combinations
by adding after the card the names of derby doubler and
finisher card.
§ 16 PICKERS 5
8. It is advisable to carefully study the combinations
just given, noticing the difference between one combination
and another, and becoming thoroughly familiar with the
order in which the machines are mentioned, so that a
knowledge of the accurate sequence of processes may be
obtained. While the foregoing combinations of machinery
are reliable and may be considered as the standards for the
class of w^ork to which they refer, it occasionally happens
that mills are found using different layouts. This may be
because the mill is intended to make a lower or a higher
grade of yarn than is customary for the numbers referred
to, or because it is a mill that has been changed over from
other numbers and the old machinery has been retained; or
there may be many other reasons.
Different opinions are held among millmen and mill engi-
neers as to the proper equipment for mills. In this connec-
tion, as \vell as in regard to all other statements concerning
cotton-mill machinery — especially as to its construction and
operation — it may be said that there is perhaps no industry in
which so much variety of opinion will be found regarding the
best methods of arriving at certain objects as in the cotton-
mill business. Not only do differences of opinion arise
among manufacturers, but a machine builder frequently looks
at a problem from a point of view differing from that of a
manufacturer. He looks on a machine or a process as a
mechanical problem to be solved, while a manufacturer looks
at it as a problem to obtain certain results effectively and
economically. Again, American practice differs considerably
in some respects from European methods. For these reasons
it is almost impossible to give definite statements of the cus-
tomary use and practice accepted by all millmen, and there-
fore the statements made are in every case, as far as possible,
either what has been found from experience to be correct,
or what the majority of manufacturers would accept as being
accurate, according to American practice.
9. A thorough comprehension of the principles of cotton-
yarn preparation can best be obtained by a careful study of
6 PICKERS §16
each machine or process in its proper sequence, including
the objects of the machine, the principle on which it is con-
structed, and the mechanism employed to arrive at its
objects; and by considering the operation and management
of the machine not only theoretically, but from actual obser-
vation. In doing this, the desired knowledge will be obtained
sooner if the combined objects of all cotton-yarn-preparation
machines are borne in mind: (1) the separation of the
matted mass of fiber into loose flakes and the removal of
the heavier and more bulky impurities, which objects are
principally attained in the opening and picking processes;
(2) the further cleansing of the stock from light and minute
particles of foreign matter by such means as are adopted
in the carding and combing processes; (3) the parallelizing,
evening, and attenuation of the fibers, as performed in the
carding and drawing processes, in the fly frames, and in
the spinning process; (4) the strengthening of the product
by twisting, as exemplified in ring or mule spinning.
COTTON MIXING
10. Receipt of Cotton at the Mill. — If cotton is
received at the mill in large quantities, as is usually the
case, it must necessarily be stored until it is required for
use. Before storing, however, it should be carefully ascer-
tained whether the quality of the cotton in each bale is equal
to the quality of the sample from which it was bought.
After this has been accomplished, all the bales of one kind,
grade, and staple (approximately) should be placed together
in the storehouse, irrespective of their original marks.
11. Objects. — When a new lot of cotton is to be used,
as many bales as it is desired to mix at one time are taken
from the storehouse to the mixing: room, where the cotton
is mixed. The objects of mixing the cotton from a number
of bales are: (1) to allow the cotton to assume its normal
condition; (2) to establish an average quality of grade in
the lot. As regards the first object it should be understood
that cotton when compressed is subjected to great pressure —
§16 PICKERS 7
so much so that the space occupied by seventy uncom-
pressed bales is often equal to that occupied by one hundred
that are compressed. Cotton, when in this compressed state,
cannot be worked so advantageously as when in its normal
condition, and for this reason should be allowed to stand
for some time after being opened before it is used.
As regards the second object of mixing, it may be stated
that, theoretically, to make a perfect product, all the fibers
should be of the same length, diameter, strength, cleanli-
ness, and color; in other words, they should be equally
matured and grown under the same conditions.
It is impossible, however, to obtain a large quantity of cot-
ton that will not vary in quality, because the lot is made up of
cotton collected from various plantations, which are probably
some distance from each other and subject to different cli-
matic conditions, different methods of cultivation, different
seed and soil. The result is that the cotton from the planta-
tion where the conditions were most favorable is in a higher
state of maturity than that raised on the other plantations.
Even in bales from the same plantation a variation is found.
An experienced cotton sampler can find points of difference —
slight in many cases, but still variations — in almost every
bale of each lot of cotton. In order to neutralize this varia-
tion as much as possible and insure a continuance of a supply
of even-running stock over as long a period as possible in the
mill, mixing the bales is resorted to.
12. Size of tlie Mixinj?. — The quantity of cotton used
in a mixing should be as large as possible; for the larger the
mixing, the easier it is to keep the work regular for a consider-
able length of time. The reason for this is that no two mix-
ings are alike, this being due not only to the variation found
in different bales of the same kind, but also to atmospheric
changes that affect the cotton, especially in regard to mois-
ture. In addition to securing regularity, another reason for
having large mixings is to give cotton from compressed bales
an opportunity to expand. By making a large mixing and
allowing it to stand for some days in a room, the temperature
8 PICKERS §16
and humidity of which are about the same as those of the room
in which the cotton is to be worked, it will be found that the
stock will run much more evenly, make less waste, and pro-
duce a stronger yarn than when used directly from the bale.
13. Metliod of Mixing. — Mixings when made by hand
should occupy a considerable amount of floor space. The
first bale should be spread over all this space, the second
bale spread to cover the first, the third to cover the second,
and so on. By this means the mixing is built up of layers
from each bale of cotton. When a mixing is used, the cotton
should be pulled away in small sections from the top to the
bottom of the mixing so as to obtain portions of each bale.
It is a good plan when using bales of different marks,
to average the mixing so that no two bales of the same
mark shall come in contact with each other. The following
rule is used to find the number of sections that should be
made in order to obtain the correct proportion of each mark
in a section.
14, Rule. — To find the mimber of sections of which a mixirig
should consist, find the largest -number that zvill exactly divide the
miniber of bales of each mark. Thoi, to find the number of bales
of each mark that there should be in each section, divide the num-
ber of bales of each mark by the member of sections in the mixing.
Example. — Find a suitable order for mixing 100 bales, the mixing to
consist of 40 bales marked ABC; 20, G H I; 10, J K L; and 30, D E F.
Solution. — 10 is the largest number that will exactly divide
40, 20, 10, and 30; therefore, the mixing should be made up of 10
sections, and in order to prevent any two bales of the same mark
coming in contact with each other, they could be arranged as follows:
• 10 times. Ans.
GH I
DEF
A BC
J KL
DE F
A BC
GH I
A BC
DEF
A BC
§16 PICKERS 9
15. It is the practice in some mills to go over the covers
of the bales after the cotton has been removed and pick off
the loose pieces of cotton adhering to them. This is a prac-
tice that should only be encouraged to a small degree, as the
amount of cotton obtained is hardly suflficient to pay for the
time occupied in its removal, and there is also a liability of
jute fibers from the burlap becoming mixed with the cotton
and causing poor work in the subsequent processes.
16. Mixing Different Varieties of Cotton. — The sub-
ject as it has been treated refers only to mixings where the
cotton of different marks is all approximately of the same
grade. Where it is desired to blend cotton of different vari-
eties for special purposes, it is not necessary that it should
be done in the mixing. For example, where it is desired to
mix exact proportions of different varieties, as American with
Egyptian, or where dyed stock of one color, or more, is to
be blended with white, the cotton may be blended to better
advantage at some of the subsequent processes.
Different growths of cotton are sometimes mixed together
for special purposes. Thus, American cotton is mixed with
Egyptian in order to cheapen the mixture, Egyptian cotton
usually being higher priced than American. By this means
a yarn is produced that practically has the qualities of a pure
Egyptian yarn; and yet the cost is less than that of pure
Egyptian. Brazilian cotton is sometimes mixed with Amer-
ican in order to increase the strength of the yarn, as Brazilian
has a strong, wiry staple; while rough Peruvian cotton is
mi^ed with Egyptian in order to give the latter woolly
qualities, the Peruvian being of a harsh, crisp nature.
Although cotton is often mixed in this way, it must be
understood that there is a certain limit to the mixing of harsh
and soft cottons, as they do not give the same results under the
same treatment in the subsequent processes; nor is it practical
to mix long- and short-stapled cotton, as the machines of the
later processes are set according to the length of the staple,
and if set for one length of staple will either damage cotton
of a different length or cause an imperfect product.
10 PICKERS §16
BALE BREAKER
1 7. Description. — A machine known as a bale breaker
is sometimes used in mixing cotton. Its object is to sepa-
rate the matted masses of cotton as they come from the bale
and to deliver the cotton in an open state to the mixing bins.
This machine, consequently, does the work that is performed
by hand in hand mixings. When using a bale breaker for
mixing cotton, a good method is to have about six bales
open around the feed-end of the machine and to take a
layer of cotton in rotation from the top of each bale. The
principle employed to attain the object of the bale breaker
is to have three or four pair of rolls, each pair revolving at
a higher rate of speed than the preceding pair. The cotton
fed to the pair that is revolving at a slow speed, is pulled
apart when it comes under the action of the pair revolving
at a faster speed. Fig. 1 shows a view of a bale breaker
with conveying aprons attached, while Fig. 2 gives an illus-
tration of the different sets of rolls that act on the cotton and
constitute the principal mechanism of this machine. Refer-
ring to these two figures, the cotton is taken from the bales
and placed on the horizontal apron a, which is moving in the
direction shown by the arrow. As the cotton reaches the first
set of rolls, it is gripped and carried forwards to the next set,
each pair of rolls having a greater circumferential velocity
than the preceding pair, the circumferential velocity of the
second pair being about twice that of the first pair, while the
circumferential velocity of the third pair is about four times
that of the second, and the last pair about five times that
of the third. The first set of rolls usually makes between
5 and 6 revolutions per minute.
The space between the different sets of rolls will be found
to vary with different makes, but usually from the center of
one pair to the center of the next is about 9 inches. The
upper roll of each set rotates in bearings having a vertical
movement, but held down by means of strong springs /'
connected with the upper rolls by means of the rods c. By
this means the upper rolls are allowed to give when an
§16
PICKERS
11
12
PICKERS
§16
excess of cotton passes between' the rolls. In the bale
breaker shown in these illustrations, the pair of rolls far-
thest from the feed-end of the machine is the largest, being
nearly 9 inches in outside diameter, while all the other rolls
are Ti inches in outside diameter. These rolls will be found
to vary in construction, in some cases being solid with flutes
their whole length, while in other cases they are made up
of rings having projecting spikes and placed side by side on
a core in such a manner that when a spike breaks it is simply
necessary to replace the ring containing the broken spike.
Fig. 2
A somewhat different arrangement of the rolls is shown in
Fig. 3, in which a series of nosed levers d are made to take
the place of the lower roll of the first set.
The cotton as it leaves the last set of rolls drops to
the lower apron <?, Fig. 1, which conveys it to the lifting
aprons/,/,. These lifting aprons have their inner surfaces
moving in the same direction and sufficiently close together
to prevent the cotton dropping down. The aprons are built
of wooden laths, with rounded edges, fastened to endless
leather belts. It is customary to construct the elevating
§16
PICKERS
13
aprons with laths at intervals that project higher than the
rest, and thus convey the cotton more positively than if all
are of the same thickness. From these elevating aprons
the cotton is delivered to horizontal aprons, which carry the
stock to the different mixing bins.
18. Care of Bale Breakers. — There are several points
that should receive attention in the care of bale breakers.
The cotton should not be fed in too thick layers, since this
Fig. 3
is liable to strain the rolls; all the dirt from underneath the
machine, which consists chiefly of sand and other foreign sub-
stances that drop from the cotton as it is pulled apart, should
be removed periodically; and what is more important, the
machine should be properly oiled. The aprons should also
be adjusted so that they will not come in contact with each
other at any point.
PICKER ROOMS
19. The room containing the machinery through which
the cotton passes during its first stages of manufacture is
known as the picker room, and its equipment for medium
counts generally consists of an automatic feeder, opener,
breaker picker, intermediate picker, and finisher picker.
14 PICKERS §16
Where the bale breaker is used, that, also, may be found
in this room, although it is usually in the mixing room.
Other machines, in some cases, may also be found in this
room, such as waste openers and waste breakers. In mills
using long-stapled cotton and producing fine yarns, either
the intermediate or the intermediate and finisher pickers
would be omitted from the above list in order to lessen the
beating action.
20. Liocation of Picker Rooms. — The picker room is
sometimes located in a building some distance from the main
mill, but if it is a part of the main building, it should be
separated by a fireproof partition or wall. The machinery
located in this room being a heavy type of cotton-mill machin-
ery and running at a very high rate of speed, also dealing
with stock in a very unclean condition, necessitates these
precautions, since, if the swiftly moving parts of the machin-
ery come in contact with any foreign matter of a hard
nature, a fire will in almost every case occur and spread
throughout the cotton. Fires occur more frequently in the
earlier processes of the manipulation of the raw stock than at
any other time. Therefore, the planning of the rooms and the
arrangement of the machinery in them must be given very
careful attention.
ARRANGEMENT OF MACHINES
21. In large mills, usually two rooms at least are
devoted to the mixing and picking, the mixing, feeding, and
opening being generally carried on in one room, while the
breaker, intermediate, and finisher pickers are located in
another room. Fig. 4 shows such an arrangement. With
the machines arranged as shown in this figure, the cotton will
be opened on the first floor and then fed to the automatic
feeder a, passing from this to the opener b and then by
trunking c to the breaker picker d, which is located on the
second floor. From the breaker picker, the cotton passes to
the intermediate picker <?, while the finisher picker / takes
the cotton from the intermediate. In case a bale breaker
were used with this arrangement, it would be situated in the
^ I
§16 PICKERS 17
opening room .^ and aprons would be so arranged that the
cotton would be carried from the bale breaker to mixing
bins situated in such a position behind the automatic feeders
that the cotton could be conveniently handled.
22. Fig. 5 shows a very similar arrangement to that
shown in Fig. 4. In this figure, however, a different method
of connecting the breaker picker and opener is adopted.
The feeder is shown at a and the opener at b. From the
opener the cotton is conveyed to the breaker picker d by
means of a horizontal trunk c. The intermediate picker e
takes the cotton from the breaker, and the finisher picker /
takes it from the intermediate.
Many different arrangements of these machines will be
found in mills. In some cases, the bale breaker, together
with the automatic feeder and opener, is located on the
second floor and connected by trunking with the pickers,
which are on the first floor. In other cases, all the machines
are in one room. In Figs. 4 and o, a dust room // is shown
under the opening room j^. This is usually constructed in
the basement, and to it are conducted the dust trunks i. The
ends of these trunks are usually provided with automatic
closing dampers /, which remain closed when the machine
from which the dirt comes is not in operation. By this
means, a draft in the trunks is prevented in case of fire, and
any back draft that would cause dust and particles of dirt to
reenter the cotton is also avoided.
FEEDING AND OPENING
AUTOMATIC FEEDER
23. Principle. — The automatic feeder is the first
machine that receives the cotton after it has been mixed, and,
as its name indicates, is used for the purpose of automat-
ically supplying or feeding another machine.
Formerly, the opener or breaker picker was fed by one of
three methods: (1) by spreading the cotton on a feed-apron
by hand, the amount depending on the judgment of the
18 PICKERS §16
operator; (2) by weighing a -certain amount of cotton and
spreading it by hand on a measured space on a feed-apron;
(3) by presenting a portion of cotton to an opening in a
pneumatic tube and allowing it to be drawn in by the air-
current. With these methods it was very difficult to obtain
a uniform feed.
Fig. 6
The principle employed in the automatic feeder is that of
having an apron with projecting spikes carry away from a
mass of cotton a larger quantity than is required, the excess-
ive amount being removed by suitable mechanism and only
that portion which is required being allowed to pass forwards
to supply the next machine. Fig. 6 is a perspective view of
the automatic feeder, while Fig. 7 shows a section. The
§16
PICKERS
19
cotton is fed by the operator to the hopper a, which should
be kept at least half full. The bottom apron a^ tends to
carry the whole mass toward the lifting^ apron a^, the cot-
ton being retarded slightly by friction with the sides of the
hopper. The spikes in the lifting apron fill with fiber from
the base to the point, and often retain comparatively large
bunches of stock. After filling, they continue to move
upwards, and the tendency for so large a number of points
Fig. 7
acting on the mass of cotton is to impart a rolling motion
to it. The stripping roll b acts continuously on the cotton
carried by the lifting apron as it arrives at the point nearest
to the stripping roll. The surface of this roll, moving in the
opposite direction from the lifting apron and only about 1 inch
from the point of the spikes, strikes off the excess cotton.
The cotton remaining on the lifting apron is the amount
necessary to supply the machine to which the feeder is
attached, and must be removed from the pins carrying it.
20 PICKERS § 16
This is done by the doffer beater r, the surface of which
moves in the same direction as the part of the apron near-
est to it, but at a greater speed. The fibers removed from
the lifting apron are in small tufts, and a certain quantity of
sand, etc. is thrown out by the centrifugal force of the doffer
beater or drops by its own weight. This passes through the
bars of the grating d into the chamber n. The cotton passes
forwards and through the passage e.
A feeder is sometimes used to take the place of the bale
breaker previously described. This feeder is constructed on
practically the same lines as the one illustrated here, although
the parts are made much heavier in order to withstand the
greater strain that is brought on them on account of dealing
with stock directly from the bale. In some mills running fine
counts, the bale breaker is dispensed with and two automatic
feeders used, the cotton as it comes from one being fed into
the other. In such cases the cotton, of course, must be
opened and mixed to a certain extent by hand.
24. Liiftiiig Apron. — The lifting apron of the automatic
feeder as generally constructed consists of an endless can-
vas sheet mounted on leather belts, to which it is fastened
by copper rivets. On this canvas sheet wooden laths are
fastened \\ inches apart. Set in the laths about 1 inch apart
are steel spikes that project from the laths about 1 inch. It
is these spikes of the lifting apron that convey the cotton to
the point desired as it is presented to them by the feed-apron.
25. Stripping Device. — Fig. 8 {a) and {b) shows detail
views of the stripping device found on the feeder shown in
Fig. 6. It consists of two rolls b, b, of wood mounted on an
iron core. An endless leather apron g passes around the
rolls; on the inside of the apron are secured strips of wood
that engage with grooves in the rolls, so that the apron ^
and roll />, are positively driven by b. These rolls are not
exactly alike in every respect, as the one nearer the lifting
apron carries pins that project through elongated holes in the
apron, as shown in this figure. At the point // the pins strike
the excess cotton from the lifting apron back into the hopper,
§16
PICKERS
21
while that which adheres to the pins is removed as the roll
revolves and the pins are drawn throu^jh the apron. In {fi)
are shown the adjustments provided for regulating the dis-
tance from the pins of the stripper comb to the lifting apron,
and thus regulating the amount of excess cotton removed;
the adjustment for regulating the tension of the apron is also
shown. In order to regulate the distance between the roll b
and the lifting apron, the casting that supports the bearings
Fig. 8
of this roll is made so that it may be moved on the frame-
work by loosening the bolts at k and turning the screw p.
The tensionof the stripping apron is regulated by the screw/,
wfiich holds the bearing of the roll d, in position.
A stripping device that differs in construction from that
shown in Fig. 8 is shown in the two sectional views, Fig. 9
(a) and (d). It consists of a metal shell that contains two
shafts a, (I,, which have bearings in the circular ends of the
shell and are capable of being moved in these bearings.
These shafts carrj'^ castings d,d,, known as trailitig levers.
On the end of each trailing lever are studs c, <r, that work
22
PICKERS
§16
in a cam -course d. The
cam is on the outside of
the shell, while the trailing
levers are on the inside;
slots e, e^ are provided in
the end of the shell for the
studs to project through,
and also in order that they
may have a certain free-
dom of movement.
Supported from the
shafts a, a-, by means of
the brackets /, /,, of which
there are several in the
length of the shell, are the
shafts ^,<^.. Each of these
shafts carries a series of
^ pointed rods hji^ that pro-
i£ ject through the surface
of the shell. As the shell
revolves and the cam re-
mains stationary, an oscil-
lating motion is imparted
to the shafts a, a^; motion
is^ also given to the shafts
g.gy., which results in one
end of the pointed rods
projecting from the shell
during a part of its revolu-
tion, while at other times
they are within the shell.
In Fig. 9 {a) is shown a
handle/ by means of which
the position of the cam
may be regulated. If it
is desired to feed more
cotton, the position of the
cam is changed so that
§16 PICKERS 23
the points will not project so far at the point where they are
nearest the lifting apron. If it is desired to feed less cotton,
the position of the cam is so changed that the points will
project farther from the shell when nearest the lifting apron
and thus strike ofif more cotton. The cam, after being
placed in the correct position, is secured by a setscrew.
In Fig. 9 id) it will be seen that when one end of a pointed
rod is projecting, the other end has been withdrawn into the
shell. By this means, any cotton adhering to the rod is
removed and falls back into the hopper.
26. Doffer Beater. — The doffer beater dififers in con-
struction in different makes of machines. In some cases it
consists of a cylinder carrying four rows of teeth that project
about 2f inches from the cylinder, each row containing as
many teeth as there are teeth in one row on a slat of the
lifting apron. Such a doffer is so placed that one of its
teeth will project between two of the teeth of the lifting
apron and be just half way between them. By this means,
as the doffer revolves, it removes the cotton from the lifting
apron and drives it downwards through the passage pro-
vided. In other cases the doffer, instead of having spikes to
remove the cotton from the lifting apron, has strips of heavy
leather projecting about 2 inches and secured to horizontal
pieces of wood mounted on a central shaft, while in still other
cases the doffer beater is constructed in such a manner that
rows of spikes will alternate with strips of leather.
Fig. 10 shows a perspective view of an automatic feeder
combined with an opener, while Fig. 11 shows a sectional view
of a similar arrangement. The feeder shown in these illus-
trations differs from that previously described principally in
regard to the manner in which it regulates the amount of
cotton fed. By referring to these figures it will be noticed
that the lifting apron is driven by a pair of cones, the ends
of which are shown in Fig. 11. The belt guide that regulates
the position of the belt on the cones is shown at,f^. By turn-
ing the hand wheel /, Fig. 10, the belt is moved on the cones
and the speed of the lifting apron regulated as may be
24
PICKERS
16
26 PICKERS §16
desired. The connection between the cones and the lifting
apron is described later. This method of regulating the
feed is frequently resorted to, as it affords a ready means
of making the necessary change. It will be seen that, if the
stripping roll should be moved too far from the lifting apron,
the cotton would be liable to be fed in lumps and thus w^ould
not be sufficiently opened. On this account it has been found
to be advisable, in ordinary cases, to increase the speed of the
lifting apron when it is desired to feed more cotton, and for
this reason most feeders, as now built, have some method by
which the speed of the lifting apron may be regulated, either
by the cone drive, as illustrated above, or by change pulleys,
change gears, or step cones. The regulation of the speed of
the lifting apron, as well as the position of the stripping roll
to give a required weight of cotton fed, is a matter of experi-
ment and observation and depends entirely on the stock used.
The passage provided in this machine for the dirt that is
struck from the cotton by the doffer beater consists of a grid d
made of metal bars set with a slight space between, them.
27. Gearing. — The gearing of the automatic feeder
shown in Figs. 10 and 11 is as follows: The doffer beater is
driven from the countershaft or main shaft of the machine
that the feeder supplies and runs at a speed of from 400 to
500 revolutions per minute. On the shaft of the doffer beater
is a 6-inch pulley that drives a 16-inch pulley on the bottom
cone. The two cones are 6 inches in diameter at their larger
ends and 3 inches in diameter at their smaller ends. On the
shaft of the top cone, a gear of 16 teeth drives a gear of
69 teeth on a shaft that extends across the feeder. A gear
of 17 teeth on this shaft drives a clutch gear of 58 teeth on
the top carrier roll of the lifting apron. This top carrier roll
is 9 inches in diameter. The feed-apron is driven from the
bottom bearing shaft of the lifting apron, on which there is a
sprocket gear of 18 teeth, which drives, by means of a chain,
a sprocket gear of 28 teeth on a roll supporting the feed-
apron. This roll is 3 inches in diameter. The wooden roll,
feed -apron and feed -rolls of the opener shown in these
§J6 PICKERS 27
illustrations are driven by means of a chain and sprocket gears
from the shaft of the top carrier roll of the lifting apron.
28. Capacity. — The capacity of automatic feeders is
very great, but since the amount of work they do is gov-
erned entirely by the requirements of the machine they feed,
they are rarely run at their full capacity. Usually about
3,000 pounds in 10 hours is the maximum amount run
through a feeder.
29. Care of Feeders. — In order that feeders may per-
form their best work, they should be kept well oiled. The
dirt should be removed periodically; the aprons should be
kept taut b\^ the tension screws provided for this purpose;
and the hopper should be kept at least half full, since the
less cotton there is in the hopper, the greater is the liability
of the lifting apron securing an insufficient amount, thus
causing the weight to vary. It is customary for one man to
attend to about ten feeders in large mills. In smaller mills
the work of feeding is combined with other duties.
The feeder requires from I2 to 2 horsepower, and occupies
a floor space of about 6 feet 4 inches by 6 feet 6 inches.
OPENER
30. The oi>ener is not used in all mills, as the auto-
matic feeder is sometimes connected directly to the breaker
picker, but in mills where this machine is used it generally
forms a combination machine with the automatic feeder, as
shown in Fig. 10. Technically, the automatic feeder ends
with the doffer beater, or, as it is sometimes called, the pin
beater. Fig. 11.
The opener has for its objects the cleaning of the heavy
impurities from the cotton and the separating of the cotton
into small tufts that are light enough in weight to be influ-
enced by an air-current generated by a fan in the succeeding
machine. It attains these objects by presenting a fringe
of cotton to a beater that makes from 1,200 to 1,800 revolu-
tions per minute. This beater usually has two blades, and
consequently for every revolution delivers two blows to the
28 PICKERS §16
fringe of cotton. By this means anj^ foreign substance will be
struck from the fringe of cotton as it is held by the feed-rolls,
and knocked through the grid bars shown in Fig. 11. The
tufts of cotton will also be removed from the fringe as soon
as they are released from the bite of the feed-rolls, and thus
they will be sufficiently light to be acted on by the air-current
that conveys the cotton to the next machine.
The cotton after being acted on by the doffer beater of the
automatic feeder falls on a feed-apron, and being separated
into small tufts, occupies so much space that the wooden roll
and feed-rolls, shown in Fig. 11. are used to condense its
bulk before being presented to the beater of the opener.
The opener alone occupies a floor space of about 5 feet by
6 feet 6 inches, and when connected with a feeder occupies a
space of 11 feet 4 inches by 6 feet 6 inches. It requires about
3 horsepower to drive it. Openers are rarely run at their full
capacity, the amount of cotton they are made to deliver depend-
ing on the amount required to supply the breaker picker.
TRUXKIXG
31. The cotton from the opener is carried along a ti-unk
to the next machine by means of an air-current that is gen-
erated by a fan. This fan exhausts the air in the trunk, and
thus the air in the room containing the feeder enters through
the openings between the grate bars in the opener, and carries
the cotton with it as it passes through the trunk to the fan.
The various forms' of trunks are as follows: (1) plain
conducti7ig triaiks, (2) horizo7ital cleaning trunks, (3) inclined
cleaning trunks.
32. A plain condiictinja: trunk consists of a circular
tube of sheet metal from 10 to 13 inches in diameter. It
should have easy curves wherever the tube bends, and should
contain sufficient doors for cleaning purposes. The inner
surface should be smooth, so as to cause as little friction as
possible in the transit of the cotton. These trunks are
used simply to conduct cotton from one point to another.
Horizontal cleaning: trunks are constructed of wood
and contain doors for the removal of the dirt, also grids
30
PICKERS
§16
through which the dirt falls. They may be built either
shallow and wide, or narrow and deep.
Inclined cleaning ti'unks are of the same construction
as horizontal cleaning trunks, but have an inclined position.
33. Fig. 12 {a), (d), and (c) shows a horizontal cleaning
trunk supported by rods / placed about 10 feet apart on each
side of the trunk. In the center of the trunk are connec-
tions for sprinklers ?-. A section of this trunk is shown
in Fig. 12 (d). The upper part is a clear passage, along
which the cotton is carried over a grating a. During this
passage of the cotton, any foreign matter that is too heavy
to be carried along with the cotton by the force of the air-
current, will drop through the grating a into, the pockets d.
Fig. 13
The portion of the trunk containing the grating is called a
cleaning trunk and does not extend the entire length of the
trunk, the remainder being simply a conducting trunk.
Forming the bottom of each pocket d are doors c hinged at d,
below which is another passage e, which has a door at each
end. Connecting with this passage ^ is a trunk /, which
extends to the dust room and contains a fan ^.
When it is desired to remove the dirt that has fallen
through the grating, the breaker picker is first stopped; the
springs that hold the doors are released; and the doors
fall, delivering the dirt into the passage e. The doors c are
then closed by means of the handles 7, and the doors at each
§16
PICKERS
31
32 PICKERS §16
end of the passage e opened. The fan g creates a current
of air in the passage <?, which carries the dirt to the dust
room. The positions that the doors assume at various times
during this process are shown in Fig. 12 (c).
If the breaker picker were not stopped during this process,
the air-current of this machine would tend to draw the dirt
back into the cotton when the doors c were opened. The
air-current of the breaker picker would also act against the
air-current of the fan g if both were running.
34. Another style of horizontal trunk is shown in Fig. 13.
The passage for the cotton and the grating are constructed
on the same principles as those just described; but the
trunk / for removing the dirt, instead of being at the end,
extends along the side of the main trunk. When it is desired
to remove the dirt, the doors c, which are made of wood and
supported by the latch .r, are dropped by pulling the ringx,,
thus causing the latch to be pulled off its support. This
forms an incline down which the dirt slides into the trunk /.
In order to prevent the dirt from falling off the sides of the
door c when it is lowered, there are boards k that form sides
as the door c drops between them.
35. One style of an inclined cleaning trunk is shown in
Fig. 14 {a) and {b). This trunk contains the usual grating a,
over which the cotton passes, while the dirt and other foreign
substances fall through this grating into the pockets b. The
bottom of these pockets is formed by c, which is capable of
being raised or lowered by the lever /. The position that
the bottom ordinarily occupies is shown in Fig. 14 (a);
when, however, it is desired to remove the dirt from the
pockets b, the lever j is brought into the position shown in
Fig. 14 {b) . In this case the bottom c is lowered into the
position shown, causing the dirt from the different pockets
to fall out into the chamber e and slide, by its own weight,
down the incline into the dust chamber.
PICKERS
(PART 2)
COTTON PICKEKS
BREAKER PICKERS
METHODS OF FEEDING
1. The breaker picker is the first machine that deals
with the cotton after it leaves the opener. This machine
may receive the cotton either directly from an automatic
feeder, or from an opener through a trunk; in the latter
case, the cotton first comes in contact with either a con-
dejiser and gauge box or a cage section. When the breaker
picker is fed directly from an automatic feeder, the cotton is
generally dropped on an apron, from which it is taken by the
feed-rolls of the picker.
2. The Condenser and Gaugre Box. — The manner of
feeding the picker by means of a condenser and jjaujre
box, when the cotton is conveyed through a trunk from the
opener, is shown in Fig. 1. The air-current that draws the
cotton from the opener through the trunk a is generated by
a fan b. After leaving the trunk, the cotton first comes in
contact with a cylinder of wire netting known as a cage,
shown at c. About two-thirds of the inner circumference of
this cage is protected by a cradle d of sheet metal, which
prevents the cotton from being drawn to this protected par*-
For notice of copyright, see page immediately following the title page
PICKERS
§17
of the cage, the air-current passing out through the ends of
the cage and down the passage ^,. The cradle d remains
stationary, but the cage c revolves in the direction shown by
the arrow, and thus the cotton, which is drawn to that part
of the cage that is not protected by the cradle, is brought
around until it comes under the action of the stripping
rolls /,^, which remove it from the cage. The roll / is held
Fig. 1
in position in pivoted bearings by the lever h, so that it wall
be as close to the cage as the bulk of cotton passing will
permit. The cotton then drops into the gauge box j and on
to the apron k, from which it is removed by the feed-rolls /, /,,
of the breaker picker.
The condenser is usiially understood to consist of the upper
part of the arrangement shown in Fig. 1, including the parts
marked c, d, f,g, and h.
§17 PICKERS 3
3. The cotton that passes through the picker is wound in
the form of a sheet on a lap roll v, shown at the front of the
machine in Fig. 1, the lap that the cotton forms being
marked x. When the lap is removed, the feeder that supplies
this machine is usually stopped and also all parts of the breaker
picker except the beaters, fans, and revolving parts of the
condenser. Since the fans continue to run during this
Fig. 2
period, the cotton that is in the trunk a \\\\\ be delivered to
the picker. It is the object of the condenser and gauge box
to take care of this stock and thus prevent the passage from
becoming blocked, by the cotton coming from the trunk.
With the arrangement shown in Fig. 1, the cotton collects,
while the picker is stopped, in the gauge box j until it is
completely filled, when any more cotton coming from the
PICKERS
§17
trunking will fall over the top of the partition m; it can then
be removed by means of the door n and returned to the
mixing. When the picker and feeder are restarted, the
amount of cotton that is in the gauge box j will supply
the feed-rolls /, K of the picker until sufficient cotton is
coming through the trunk a.
Fig. 2 is a perspective view of a picker with a condenser
and gauge box.
4. Cage Section. — A sectional view of a breaker picker
that receives the cotton by means of a cage, or screen, section
Fig. 3
is shown in Fig. 3, while Fig. 4 is a perspective view. An
air-current generated by a fan b draws the cotton from an
opener through a trunk a to two cages, or screens, <:,<:,.
These cages are protected so that as the air-current passes
out through their ends, down the flue bi to the dust room,
the cotton is drawn to the portions of their circumferences
nearest the delivery end of the trunk a and, as the cages
§17
PICKERS
revolve in the direction shown by the arrows, is condensed
in a sheet between them; it is removed by the stripping
Fig. 4
rolls /,^ on to a stripping plate r, from which it is removed
by the feed-rolls /, h of the picker.
CONSTRUCTION AND OPERATION OF THE
BREAKJZR IMCKER
5. Objects of the Breaker Picker. — The objects of
the breaker picker are: (1) To remove foreign matter,
especially the heavier and larger impurities, such as dirt,
pieces of seed, leaf, etc.; (2) to separate the tufts of cotton
so that they may be more easily manipulated at the next
process; (8) to form the cotton into a layer and wind it on
a roll in a cylindrical form known as a lap.
^17 PICKERS 7
The method used to attain these objects is to have a rapidly
revolving beater strike a fringe of cotton, which is presented
to it by a slowly revolving pair of feed-rolls, thus breaking
up the sheet of cotton into small tufts and striking off any
foreign matter in the cotton. The process of cleaning is also
aided by an air-current, which draws dust from the cotton
through screens, or cages, to which it is being drawn. These
cages revolve and deliver the cotton in a sheet ready to be
wound into a lap by means of a lap liead.
6. Pickers are known as pickers in single section or pickers
in doxible section according to whether they give a single or
a double beating action to the stock passing through them.
Breaker pickers in single section are shown in Figs. 1, 2,
3, and 4. The passage of cotton through breaker pickers in
single section, whether they are fed by a condenser and
gauge box, as in Fig. 1, or by a cage section, as in Fig. 3,
is the same. Referring to Fig. 1, after the cotton delivered
by the feed-rolls /, /^ has been struck by the rapidly revolving
beater a^, it passes over grid bars c. in order that any dirt or
other foreign matter may be separated and fall through the
spaces between the bars. Then it is carried over inclined
cleaning, or grate, bars / so that other foreign matter, too
heavy to be carried by the air-current, may have an oppor-
tunity of dropping through the spaces between the bars. This
cleaning process is continued while the cotton collects in a
layer on the surface of two revolving cages, or screens, ^, d',,
through which a current of air is drawn by a revolving fan k.
The cotton, now in the form of a sheet or layer, is removed
by stripping rolls p, and allowed to pass over a stripping
plate r, between smooth calender, or presser, rolls 5, 5,, ^,,53,
between rolls s^ and /, and around the lap roll v that rests on
the fluted calender rolls /, /,, thus forming the lap x.
7. Fig. 5 shows a section through a breaker picker in
double section with what is known as a porcjipine beater.
This picker is connected directly to an automatic feeder
by means of an apron, a portion of which is shown. In
case a picker in double section is fed by trunking from
PICKERS
§17
an opener and feeder combined, the cotton is delivered to
a cage section similar to that shown in Fig. 3, while a
beater of the type shown at «,, Fig. 5, usually replaces the
porcupine beater.
Referring to Fig. 5, as the cotton is delivered to the
picker by the feed-apron, it is taken by feed-rolls b, b^, from
which it is struck by a beater a that is rapidly revolving in
the direction shown by the arrow. It then passes over grid
bars <r, through which dirt and other foreign matter fall; then
over inclined cleaning, or grate, bars / to cages ^, ^i, from
which it is delivered in a sheet to rolls //. These rolls
deliver it to a stripping plate //,, from which it is taken by
Fig. 6
rolls y and delivered to a beater a^, which strikes it down
over grid bars /. It then passes over cleaning bars m to
cages ;/, ?/,, which deliver it in a sheet to rolls p, from
which it passes over a stripping plate r; then between
rolls 5, 5,; 5^,, s.,; s., S:,; under roll ^4, over roll /, and is finally
wound in the form of a lap on a lap roll v.
8. Types of Beaters. — There are several types of
beaters, that known as a porcupine beater being shown in
elevation at a, Fig. 5, and in perspective in Fig. 6; it con-
sists of steel projections riveted to circular metal plates.
This style is a special make and is most frequently found on
openers. A carding beater is shown in section in Fig. 7,
§17
PICKERS
9
and in perspective in Fig. 8; this beater has been adopted in
recent years. It consists of three wooden lags a^ a, a that are
securely fastened to the arms b, b, b of the beater, which is
mounted on the shaft c. Steel pins d, d, d, arranged spirally,
project from the lags, those pins that first come in contact
with the cotton being shorter than the others, as shown in
Figs. 7 and 8. With this arrange-
ment, the pins penetrate and break
up the cotton, and as they enter
it gradually, the strain incident to
the operation of picking is almost i],
equally distributed among them,
causing the beater to combine a
carding and a beating action.
The carding beater is used to
the greatest extent in breaker
pickers and sometimes, though
not often, in intermediate pickers.
Another type, and one that is more commonly met with,
is known as the ordinary knife, or rigid-blade, beater.
A two- and a three-blade beater of this type are shown in
perspective in Figs. 9 and 10, respectively. The edges of
the blades should not have a knife edge, neither should they
4
Fig. 7
be too blunt. As soon as the edges wear, the beater should
be turned around so that the other edges of the blades will
come in contact with the fringe of cotton. When both
sides are dull, suflficient metal should be planed from the
blades to give two new edges on each. Sometimes, beaters
10
PICKERS
17
are constructed with hardened steel edges fastened to the
blades; these edges may be replaced when necessary.
9. Action of the Beater. — The action of the beater is
the most important part of picking; for it is desired not only
to clean the cotton, but also to do this with as little injury
Fig. 9
to the fibers as possible. The speed of the beater must
therefore be so regulated that the blades will not strike the
cotton too often and thus injure the staple; neither should
the speed be so low that they will not strike the cotton often
enough and thus not clean it sufficiently. Beaters as a rule
should not strike more than about 60 nor less than 20 blows
per inch of cotton fed.
The speeds of beaters vary considerably, but the following
Fig. 10
are about the maximum and minimum for the different
machines and types:
Porcupine beater, 30 inches in diameter, in opener, 500 to
600 revolutions per minute; 18-inch, two-blade, ordinary knife
beater in breaker, 1,400 to 1,600 revolutions per minute;
20-inch, three-blade, ordinary knife beater in breaker, 850 to
§17
PICKERS
11
•1,050 revolutions per minute; 16-inch, two-blade, ordinary
knife beater in intermediate or finisher, 1,250 to 1,500 revo-
lutions per minute; 18-inch, two-blade, ordinary knife beater
in intermediate or finisher, 1,200 to 1,450 revolutions per
minute; 18-inch, three-blade, ordinary knife beater in inter-
mediate or finisher, 800 to 950 revolutions per minute.
10. The fnvUl bars through which the beater knocks the
impurities are important agents in the cleaning of the cotton.
They are triangular in section and extend from one side of
Fig. 11
the machine to the other. There are a sufficient number of
them to occupy an arc of a circle extending for about a
quarter of the path of the beater. When using 1-inch
American cotton, the bar nearest the feed-roll is usually set
in such a manner that the beater blade in revolving will be
about 2 inch from it when at its nearest point, while the last
bar should be about f inch from the beater blade when at its
nearest point. Thus, the arc of the circle formed by the
bars is not concentric with that formed by the path of the
beater blade. The reason for setting the bars in this manner
12
PICKERS
§17
is that the cotton expands and tends to fly from the beater
blade, as the beater revolves, and thus would come against
the bars if they were too near. The angle at which the bars
are set, as well as the distance between them, also form
important points in the setting of this part of the picker.
The bars close to the feed-roll should have more space
between them than those more distant. For 1-inch American
cotton, there is usually about 2 inch from edge to edge of the
first three bars, while the lower bars are about t inch apart.
Fig. 12
11. An adjustment for setting the grid bars is shown
in Fig. 11. The upper six bars a are of the ordinary pattern
and through these the heavier forms of leaf and dirt are
ejected by the action of the beater. The dirt that passes
through these bars falls into a separate chamber, and, as the
small capacity of this chamber will prevent any strong cur-
rent issuing in the opposite direction through the bars, the
impurities are prevented from returning. This advantage is
further augmented by arranging the last five bars b so that
they are adjustable. By this means an almost perfect regu-
lation of the current of air passing upwards through the
bars a can be obtained; for, the more air passing through
the bars /', the less will pass through the bars a. The bars b
§17
PICKERS
13
are also arranged to prevent by their shape, as far as possi-
ble, any return of dirt that may be driven through them by
the beater. The adjustment is made by means of sliding
plates b,, into which the lower parts of the bars loosely fit.
These plates can be moved backwards or forwards by a
handle c, which, when set correctly, can be firmly fixed in
position. The division plate d is an important factor and
must be set accurately to obtain the best results.
12. Stripping Rail. — As soon as the cotton is released
from the feed-rolls b, b,, Fig. 5, it is acted on by the beater
and then by an air-current that is generated by the fan d.
Fig. 13
This fan exhausts the air in the passage between the beater «■
and the cages e, e^, and thus the air rushes in from the room
through the opening shown in the side of the picker, passes
through the grid bars r, through the passage to the cages,
out at the ends of the cages, and down a flue to the dust
room. By this means the cotton is carried through the
passage over the cleaning bars / to the cages e, <?,. The top
of the passage projects to some extent toward the beater
and supports what is known as the stripping rail, one type
of which is shown in Figs. 12 and 13 at a. It is the function
of this rail to remove any cotton that has adhered to the
beater instead of being carried to the cages. In some cases
14 PICKERS §17
the stripping rail cannot be moved, while in other cases it is
capable of being adjusted. The type of stripping rail shown
in Fig. 12 is an adjustable one, as the rail a is entirely
separate from its support b. The adjustment for the strip-
ping rail is shown in Fig. 13. Although the stripping rail is
described in connection with a porcupine beater, it is gener-
ally and more appropriately used in connection with two- or
three-blade beaters.
13. Inclined Cleaning Bars. — The bottom of the
passage between the beater and the cages is formed by the
series of cleaning bars /, Fig. 5, known as the inclined
cleaning, or grate, bars. These bars are so placed that
any foreign matter that is too heavy to be carried along by
the air-current will drop of its own weight through them and
thus be prevented from reentering the cotton. Every fifth
bar is a deep one, in order to prevent the dirt that drops
between the bars at a point nearest the cages from sliding
down the incline. If this were not provided for, considerable
dirt would accumulate at the lowest point of the incline and
make it possible for a portion, at least, to reenter the cotton,
as underneath these bars is a door.^, Fig. 5, that is held in
place by a weight on a lever, a portion of which is shown
at ci\. This door can be lowered, in order to remove the
dirt that has accumulated, but the picker should be stopped
when this is done so that the air-current will not enter the
passage to the cages through the grate bars and thus take
some of the dirt with it into the cotton that is being drawn
to the cages.
The cages e,e^. Fig. 5, on which the cotton is delivered
from this passage, are similar in construction to those that
have been described, and are usually about 22 inches in
diameter; in some cases, the top one is larger than the
bottom one, or vice versa.
14. At a point ^.. Fig. 5, is a block that prevents air or
cotton from being drawn to the surface of the upper cage
beyond this point; the framework ^^ accomplishes the same
object for the bottom cage. These cages are also usually
§17
PICKERS
15
protected at the ends and other places so that the cotton
cannot be drawn to any point but that nearest the passajje.
The cages aid in the cleaning of the cotton, since, as it is
brought with some force against them, dust and foreign
matter small enough to go through will be carried to the
dust room. In addition to this, the cages, by revolving,
Fig. 14
form the cotton into a layer, which is taken by the stripping
rolls h and delivered on the stripping plate //,.
The cotton next passes over this stripping plate and is
gripped by the feed-rolls j; in passing from these to the
stripping rolls p, it is treated in the same manner as during
its passage from the feed-rolls b, b, to the stripping rolls //.
16 PICKERS §17
In this section of the picker, however, there is a different
type of beater, and the air-current is generated by the fan k,
the air passing in through the grid bars /, and carrying the
cotton over the cleaning bars m on to the cages w,?/,, from
which it is stripped by rolls p and delivered on to the plate r.
The cotton passes from the plate ;-, between the rolls ^ and 5,.
then between s, and s^, between s. and s^, and under the
compression roll s^. The object of the last roll is to further
condense the cotton. It has no bearings, being held in
position by the rolls ^3, t and receiving motion by frictional
contact with them; this roll is also shown at ^4, Fig. 14.
The rolls s,s^,s.,S:, are known as smooth calendei* rolls,
and their purpose is to condense the layer of cotton. Their
bearings are held in vertical slides, so that they are capable
of being separated slightly when an excessive amount of
cotton passes through. If they were held in fixed bearings,
considerable strain would be brought on them at such a
time. Two of these rolls that are not adjacent are con-
structed with collars, so that the four rolls fit into each other,
as shown in s,s.,,s.,S:,, Fig. 14. In addition to their own
weight, downward pressure is exerted at each end by a
weighted lever attached to two rods, one suspended from
each side of a saddle resting on the bearings of the
upper roll.
15. Lap Roll. — Between and resting on the fluted calen-
der rolls /, ty is the lap roll i\ which is held in position as
shown in Fig. 5. This roll is revolved by frictional contact
with t and /,, and serves to roll the cotton into a cylindrical
form known as a lap. When the lap has reached the desired
size, the lap roll is withdrawn and the lap removed from the
machine. The lap roll, which is also shown in Fig. 14 at v,
is built in two styles; sometimes it is solid, and when the lap
is used at a succeeding process a rod is pushed through the
opening thus made, while in other cases it is hollow, so that
a rod having a large, flat head may be inserted while the lap
is still on the lap roll and thus be in position when the roll is
withdrawn from the lap.
§17
PICKERS
17
16. Lap Rack.— In order to build a solid lap, a device
known as a lap rack is employed, the construction of which
is shown in Fig. 15 (a) and {d), Fig. 15 (a) being a side
Fir,. 15
elevation and Fig. 15 (d) a plan view, partly in section. At
each end of the lap roll v is the lap rack a, the upper part of
which has a bearing on the lap roll; the lower part has teeth
that engage with a gear /? on the shaft r. Fixed to the shaft c
1^181
Caffe
Bottom Stripping Roll
Top
S3
i'Oia
IS Dia.
[|
37
33- j :: i Bottom Feed Roll 2 "Dia.
y
Beater 1450 R.PM.
18t
LlJ Bottom Stripping Roll
Top
t^
Top Calender Roll 5'/^" Dia.
2nd
3rd
90 HS
17.
'^
Bottom „
-39
.23
1=^30
Cross Sfiaf l
2lMs
27
^ [-
Back Fluted CalenderRollOiyia.
Front
^2*
22
'24
§17 PICKERS 19
is a gear d that meshes with a gear ^ on a sleeve on the
stud n. This sleeve also carries another gear / that meshes
with the gear g loose on the shaft c and compounded with
the friction pulley in. Pressing against this friction pulley
is a strip of leather, which is held against it with considera-
ble pressure by means of the weight p on the lever / ful-
crumed on ;/.
As the lap increases in size on the roll v, it must overcome
the total resistance of the friction pulley and the friction of
the gearing; by this means it is made comparatively firm.
When it is necessary to remove the lap, the friction is
released by depressing the end of the lever /, opposite to
the weight p, with the foot. The cotton then has a tendency
to expand, which will lift the racks a, to some extent, but
they are further raised by means of a hand wheel, shown
at >', Figs. 2 and 4, and which is on the shaft c. Fig. 15 {a).
17. Gearing. — Above the machine in Fig. 5 is shown a
framework carrying a countershaft x. The speed of the
beater is so high that it cannot be driven directly from the
main shaft of the room without using very large pulleys; for
this reason, the countershaft is used and the beater driven
from it as shown in Fig. 5. In some cases instead of being
on the machine the countershaft is attached to the ceiling.
A plan of gearing for a picker in single section having a
cage section is shown in Fig. 16. On one end of the beater
shaft a are two pulleys «,, a.\ a^ drives the fan that pro-
duces the air-current for the cages nearest the lap head,
while a^ drives the fan that produces the air-current neces-
sary to draw the cotton from the trunking to the cage section.
These pulleys are 6 inches in diameter and drive pulleys on
the fan shaft 8 inches in diameter; therefore, when the beater
shaft a is making 1,450 revolutions per minute, the speed of
each fan is — ^-^ — — — = 1,087.5 revolutions per minute.
8
On the other end of the beater shaft is a 4-inch feed-
pulley a., driving an 18-inch pulley compounded with a
15-tooth gear, which, through two gears connected, or
20 PICKERS § 17
compounded, by a clutch arrangement, drives a cross-shaft b,
from which the fluted calender rolls receive motion. At the
other end of the cross-shaft from the 12-tooth gear driving
the fluted calender rolls is a gear of 14 teeth, driving a gear
of 50 teeth, which is compounded with a gear of 27 teeth.
The method by which the calender rolls, stripping rolls,
and top cage are driven from this gear of 27 teeth may be
readily traced. The bottom cage is driven from the top
cage. The 14-tooth gear on the cross-shaft b drives a
30-tooth gear on the end of another cross-shaft c through
the 50-tooth gear. The shaft c, by means of bevel gears,
drives a shaft extending along the side of the picker. The
feed-rolls receive motion from this shaft, and the stripping
rolls, together with the cages of the first cage section, are
driven from the bottom feed-roll.
18. The cross-shaft /' that carries the gear of 14 teeth is
driven through the 18-inch pulley by a 35-tooth gear, a clutch
gear, and a 17-tooth gear meshing with one of 90 teeth on
the cross-shaft. When the clutch is disconnected, the lap
head and the feed-rolls will stop, but the beater and fans will
continue to run. When it is desired to remove a lap, this
clutch is disconnected.
The reason for this construction is that the beater and
fans, owing to their high speed, could not be stopped imme-
diately when it was desired to remove a lap without putting
an excessive strain on the beater; neither would it be advis-
able to start the beater and fans from a standstill each time
the feed was started, since too much time would be required
for these parts to acquire their maximum speed. By this
construction, however, the cotton may be stopped or started
through the picker almost instantly.
19. Draft of a Breaker Picker. — The draft of a
breaker picker is usually a little less than 2. and is figured
from the fluted calender rolls to the feed-rolls. The draft
of the picker shown in Fig. 16 is
9 X 24 X 12 X 30 X 24 X 28 X 33 ^ j g^r,
24 X 53 X 14 X 24 X 28 X 37 X 2
§17 PICKERS 21
20. Floor Space of a Breaker. — The floor space of a
breaker varies according to the style and make of the machine.
One type of a single-beater breaker with a cage section occu-
pies a floor space of 13 feet 9 inches by 6 feet 8^ inches,
allowing for trunk connections. A double-beater machine,
other particulars as above, occupies 19 feet 10 inches by
Fig. 17
6 feet 82 inches. Where a condenser and gauge box are used
instead of a cage section, from 7 to 9 inches may be deducted
from the length given above. These measurements are for
pickers that make laps 40 inches wide.
When in single section, breaker pickers require about
4i horsepower; when in double section, about 7 horsepower.
§17
PICKERS
23
The production depends on the speed, width of lap, and
weight of lap pei" yard. A common production is about 500
pounds per hour, or 25,000 pounds for a week of 50 hours
actual running time, as about 8 hours is allowed for
stoppages.
INTERMEDIATE AND FINISHER PICKERS
21. Intermediate and finisher pickers are prac-
tically alike in construction and differ very little from a
breaker picker in single section. Their objects are the same
as those of the breaker picker; the lap that they produce,
however, is of a more uniform weight per yard.
Fig. 17 shows a perspective view of a finisher picker, while
Fig. 18 shows a section through the same machine. Four
Fig. 19
laps taken from the previous picker are placed on the apron a,
and thus the advantage gained by doubling is secured.
22. Fig. 19 shows how the laps pass under each other
on the apron that conducts them to the feed-rolls. Rods
passing through the centers of these laps and being in contact
with the brackets a^, a„., a^, a^, Fig. 18, hold the laps in position.
The laps, shown in Fig. 19, vary in diameter. This is
necessary in order to keep four layers of cotton supplied to
the feed-rolls at all times. If all the laps were of the same
diameter, they would run out at the same time, and thus
there would be a liability of the cotton running through
the machine before all the new laps were supplied, as well
as a tendency to irregularity through four piecings coming
near together.
24
PICKERS
17
§17
PICKERS
25
EVENER MOTIONS
23. After it is delivered by the feed-rolls, the cotton is
treated in the same manner as in the breaker picker, but the
manner in which it is fed into the intermediate and the
finisher pickers is somewhat different from that in a breaker
picker, as indicated by the curved section plate d above the
roll r, Fig. 18. This section plate is a portion of a motion
known as the evener
motion, the object
of which is to regu-
late the speed of the
feed-roll in accord-
ance with the weight
of cotton fed so that
a uniform weight will
be presented to the
beater.
Fig. 20 is a com-
plete view of all the
attachments of an
evener, while Figs. 21
and 22 are portions
of side elevations.
A shaft b. Fig. 20,
carries rolls b^, which give motion to and support the feed-
apron a. Fig. 18, while c, Fig. 20, is a feed-roll, or evener
roll, extending across the machine.
Fig. 21
24. Scale Box. — Fig. 20 shows eight sectional plates d,
each of which is about 5 inches in width, and carries a pro-
jection d^ that passes inside a box known as the scale box e.
The plates are connected in pairs by four short saddles ^,.
Each pair of these saddles e^ is, in turn, connected by a larger
saddle e.,, while the centers of e.. are connected by a still
larger saddle ^^.
Extending from the center of the saddle e^ is a pin <".,
which projects out of the scale box and forms a bearing for
26
PICKERS
§17
a lever / at A. The fulcrum of the lever is at /^ and is
formed by a bracket fastened to the scale box. At the
other end of the lever, fastened at /a, is a vertical rod ^
that is connected to a short shaft ,^i at the side of the
picker. At the opposite end of this shaft is fastened a
segment //, the teeth of which engage with a gear /i^. This
Fig. 22
gear is on a sleeve with a gear /i^, the sleeve being sup-
ported by a stud that projects from a bracket bolted to the
framework under the apron. Supported from this same
part of the machine are bearings /, /, that hold a rack k in
position. The teeth of this rack engage with the teeth of
the gear /i^.
§17 PICKERS 27
25. Connected to the rack k is a belt guide k, that
controls the position of the belt on the cones and thus regu-
lates the speed of the driven cone. A rod /, that extends
downwards from the bearing j\ and then horizontally through
a projection on the belt guide serves to steady the guide.
26. Feed-Roll. — The manner in which the feed-roll is
driven through the cones may be seen by reference to
Figs. 21 and 22 in connection with Fig. 20. On the beater
shaft m is a pulley w, driving a pulley w^ on a shaft w that
extends across the picker. The lower-cone shaft is driven
from the shaft 7i by the gears w,, w„ while motion is imparted
to the top-cone shaft by a belt that passes around both cones.
On one end of the top-cone shaft is a spiral gear/, Figs. 20
and 22, that drives a spiral gear p^ on a short shaft g. At the
other end of this shaft is a double worm r that drives a
worm-gear r, of 78 teeth. Compounded with the gear r, is a
gear r^, which is of extra width so that it drives a gear 7\ on
the feed-roll and also a gear )\ on the apron shaft h.
27. Opei'ation. — The manner in which this evener regu-
lates the speed of the feed-roll in accordance with the weight
of cotton fed is as follows: The sectional plates d, Fig. 20,
are pressed dow^n on the roll c by the weight /., shown on the
lever /, through the connection made by e^ and the saddles.
The distance that these plates are raised from the roll c is
governed by the amount of cotton that passes between them
and the roll; and, by following the connections, it will be
seen that the distance these plates are raised will govern the
position of the belt on the cones, and, consequently, the
speed of the roll c that feeds the cotton.
When the proper weight of cotton is being fed uniformly
throughout the length of the feed-roll r, the plates are raised
the same distance from the roll c and the belt should be
exactly in the center of the cones. If, however, a portion of
cotton 1 inch thicker than the average thickness comes under
the section plate at the extreme left, this section plate will
be raised 1 inch from its normal position. The result of this
will be that the end of the lever Ci resting on this plate will
28
PICKERS
§17
be raised 1 inch, which in turn will raise the end of the lever e.
connected to e^ \ inch. The end of the lever e^ that is
connected to this lever e^ will therefore be raised \ inch,
which, by causing the pin e^ to be raised & inch, will result in
the lever / being raised h inch at the point /,.
As the lever / cannot rise at A, its other end must rise
and, through the rod g, turn the shaft g^. The segment h
Fig. 23
wall therefore be moved, and through the gears //,, lu and
the rack k, the belt will be guided on to the smaller part of
the lower, or driving, cone, thus decreasing the speed of the
feed-roll and reducing the weight of cotton fed. As soon as
this heavier portion of cotton has passed and the correct
weight is fed, the parts will be brought to their normal
positions by means of the weight on the lever /.
SI-
PICKERS
29
In this illustration, an extreme case has been taken, as it
is seldom that an extra portion of cotton 1 inch thicker than
the average comes under one of the section plates; but the
belt would be moved the same distance if a portion of cotton
H inch thicker than the average should come under all the
section plates. If four of the plates are raised i inch from
Fig. 24
their normal position, it will have the same effect as raising
each plate i inch. It is therefore obvious that the arrange-
ment is designed to insure an average weight of cotton being
fed regardless of the number of plates that are affected.
28. Another type of evener is shown in Figs. 28 and 24.
Extending across the machine between the apron roll and
§17 PICKERS 31
the feed-rolls is a plate a, Fig. 23, that has a sharp edge on
the top. Bearing on this are eight sectional plates a. that
are in a position to be affected by the cotton just before it
passes to the feed-rolls b, /$>,. The lower feed-roll is smaller
than the upper one, and thus the plates are allowed to lie
under the upper one and so come very close to the bite of
the rolls. Arms a^ extend from these plates under the feed,
or lap, apron, as shown in Figs. 23 and 24, and are connected
in pairs by means of bridges c, c, which, in turn, are connected
to a large bridge c, by means of two other bridges <:,,<:,.
Fulcrumed at ^ is a lever d^ that contains a screw d^ having a
bearing on the large bridge c^. Extending from this lever d^
is a rod e that connects with shaft / having bearings at A
and A. At the end of the shaft / nearest the bearing f, is
attached a segment ^, the teeth of which engage with a
rack gy that governs the position of the belt h^ on the
cones //,//,.
The bottom cone h is driven by gearing from the side
shaft j, which receives motion from the lap head. The top
cone hi, driven by the bottom cone, drives the feed-rolls by
means of a worm-drive; consequently, any movement of the
belt on the cones will alter the speed of the feed-rolls and
thus affect the weight of the cotton fed.
When the proper weight of cotton is being fed, the plates
are all depressed the same distance; but, if a portion of
cotton heavier than the average weight passes over a plate,
this plate will be further depressed. As the plate is ful-
crumed on a, this will cause the outer end of the arm a^ to
rise, which will result in the lever d^ being raised through
the connections made by the bridges c,c-,,c^. The raising of
the lever d^ will impart motion to the shaft / by means of the
connecting-rod e, which will cause the segment g to move
the rack g^ in such a manner that the belt h. will be moved
to the small end of the driving cone. When the heavy
portion of cotton has passed, the plate will be returned to
its normal position by the weight of the arm a,, together
with the weight of the bridges, lever, and connecting-rod.
If less than the average weight of cotton is presented to the
32 PICKERS §17
plates, the arm a., and the lever ^/,, together with the bridges,
will fall, because of their weight, and the result will be that
the belt will be moved to the larger end of the driving cone,
thus increasing the speed of the feed-rolls.
29. A picker with another type of evener motion attached
is shown in Fig. 25. The scale box and its connections with
the segment resemble those in Fig. 20. The rolls of this
evener, however, instead of being driven merely through
cones, are driven by a combination of two cones, a drum,
and a roll.
The manner in which this method of driving is arranged
can be readily traced. A side shaft /, Fig. 25, that carries
a drum k at one end receives motion from the lap head.
A belt / from the drum k passes first over a roll ni and then
around the cones «,,«. The feed-rolls receive their motion
through a worm-drive from the top cone n.
It is possible to attach eveners to automatic feeders,
although this is not commonly done, since the effect of the
evener on the uniform weight of cotton is destroyed to some
extent during its passage from the feeder to the breaker
picker, especially if an opener is used and the cotton is con-
veyed from it to the breaker picker by trunking.
MEASURING MOTION
30. The measuring motion is used to a greater extent
on intermediate and finisher pickers than on breaker pickers.
Its object is, when a definite length has been wound on the
lap roll, automatically to stop the feed-rolls, the smooth
calender rolls, and in some cases the fluted calender rolls,
while the beater shaft and fans continue to revolve.
A view of a measuring motion, the value of the gearing of
which is given later in this Section, under Gearing, is shown
in Fig. 26; a represents the end of the bottom calender roll,
carrying a worm b, which through a worm-gear c drives a
shaft <:, carrying a bevel gear d, which drives a bevel gear e.
The gear e, together with a dog /, is loose on a stud g and
carries a projection e^, the dog / also carrying a projection /,.
§17
PICKERS
33
The dog, if allowed to do so, would fall because of its own
weight so that its point would be down, but as the gear e
receives motion from the bottom calender roll, the projec-
tion e^ on the gear e comes in contact with the projection /,
on the dog / and thus continually forces the dog around
ahead of it; consequently, when the projection e^ is at its
highest position, the parts mentioned occupy the position
shown in Fig. 26.
As the gear e continues to revolve, the dog / will be
brought in contact wath a projection on a lever h that is
Fig. 26
connected to the starting levei h^ fulcrumed at h._. Con-
nected to //i is a rod j. Figs. 22 and 26, that runs along the
side of the picker and connects with a double worm r, Fig. 22.
A bracket k, Fig. 26, is also attached to the rod h^, while
attached to this bracket is a rod k^ that connects with the
clutch /, Fig. 27, through which the lap head is driven.
31. When the picker is running, the cut-out, shown in
dotted lines, in the lever h. Fig. 26, has a bearing on a cast-
ing, and thus the starting lever /^, is held in such a position
that the worm r, Fig. 22, is in contact with the worm-gear r,,
34 PICKERS § 17
the clutch /, Fig. 27, being closed. When, however, the
gear c. Fig. 26, has made one revolution and has brought the
dog / into contact with the lever h, any further movement
causes the dog / to force the cut-out on // from its bearing.
This causes the starting lever h^ to drop, disconnecting the
clutch /; the worm ;' is also thrown out of gear, causing the
calender rolls and the feed-rolls to stop.
In some cases, the gearing is so arranged that only the
smooth calender rolls and the feed-rolls stop, while the fluted
calender rolls continue to run, thereby resulting in the lap
of cotton being broken away from the sheet of cotton
held by the rolls that have been stopped. In other cases
the fluted calender rolls stop and the lap is broken from
the cotton in the machine by giving it a partial revolution
with the hands.
After the lap has been thus separated, the racks described
in connection with Fig. 15 are raised, the roll v withdrawn,
and the lap is removed from the machine. The starting
lever //,, Fig. 26, is then raised until the cut-out rests on the
casting, thereby throwing the clutch /, Fig. 27, and the
worm r. Fig. 22, into gear, and starting the cotton through
the machine. The lap roll is then placed in position and the
layer of cotton started around it by hand, after which the
foot is placed on the lever /, Fig. 15, allowing the racks to
descend by their own weight and hold the lap roll in posi-
tion. This operal;ion is repeated each time the gear ^ makes
one revolution and releases the lever //, Fig. 26.
ADJUSTMENTS
32, The distance between the blade of the beater and
the feed-rolls when in closest proximity is an important
point in a picker. If this distance is too great, the fringe of
cotton will not receive the full benefit of the beating process,
and thus the impurities will not be properly removed or the
cotton separated into sufficiently fine pieces. On the other
hand, if the beater blade is set too close, the fibers of the
cotton will be injured.
§17 PICKERS 35
An adjustment is therefore provided for moving the feed-
rolls nearer to, or farther from, the beater. The reason for
moving the feed-rolls instead of the beater is that, as the feed-
rolls revolve much more slowly than the beater, they would
not be injured as much if, after changing their position,
their bearings were not exactly in line. The distance
between the blade of the beater and the feed-rolls is depend-
ent principally on the length of the staple being run, the
diameter of the feed-rolls, and the thickness of the cotton
being delivered to the beater.
The longer the staple, the smaller the diameter of the
feed-rolls, and the thicker the cotton being delivered, the far-
ther the feed-rolls should be set from the beater. With
3-inch feed-rolls, and using 1-inch American cotton, the dis-
tance between the blade of the beater and the feed-rolls
should be from ttb to t^ inch.
33. Evener Adjusting Screw. — Near the top of the
rod g, Fig. 20, is shown an adjusting screw ^2. Sometimes,
owing to atmospheric changes and other conditions, the
weight of the cotton will vary; that is, it may feed a little
heavier or a little lighter one day than another. This causes
the weight of the lap per yard to vary also. As the same
weight of lap per yard is usually required each day, an
adjustment must be provided by means of which the variation
may be reduced to a minimum. If the lap is delivered too
heavy or too light per yard, a change, of course, can be made
in the draft change gear, but in case the variation is very
slight, a change of 1 tooth in the draft gear will probably
cause too great an alteration. For this reason, therefore,
the adjustment is provided on the rod g and, by turning the
screwy, up or down on this rod, the belt may be moved on
the cones, thus making a very slight change in the speed of
the feed-rolls. All evener motions are provided with some-
what similar adjustments.
Draft dears
V\ m
tr^^=Jt=^
Beaipr 1450 R.RM.
S
Car/c
czzf
Top
Top CulencIerRoU 5'/2"Dia.
2 "J/
1= 3':^
Bottom
Cross Shaft
O'Din.Lap CalpnderRotl
C 9"
cd Bottom StrippinffRotI
27
Fig. 27
17 PICKERS 37
GEARING
34. The gearing of a picker equipped with the evener
motion illustrated in Fig. 20 is shown in Fig. 27. The beater
shaft m is driven from a countershaft, as explained in con-
nection with the breaker picker, and carries the usual pulleys
for driving the fan and feed-rolls.
The feed-pulley Wi drives a pulley i?i^ on a shaft ?/ extend-
ing across the picker. From this shaft, the cones and the
feed-rolls, together with the feed-apron, are driven. As the
feed-apron is driven through the cones, its speed will always
be in accordance with that of the feed-rolls. The lap head,
cages, and stripping rolls are driven through a side shaft p,
which receives its motion from the shaft ?i. The driving plan
of the picker shown in Fig. 25 is given in Fig. 28.
The measuring motion is provided with change gears,
by means of which different lengths of laps can be procured.
When finding the length of lap, the number of revolutions
made by the bottom calender roll while the knock-off gear is
revolving once should first be determined; this result multi-
plied by the circumference of the roll will give the length of
lap. Referring to Fig. 26, the bottom calender roll a is
7 inches in diameter, b is a. single worm, and the worm-gear c
is the change gear; the gear d has 21 teeth, while the knock-
off gear e contains 30 teeth.
The length of lap delivered when using a 45-tooth change
30 X 45
gear is as follows: = 64.285 revolutions of roll to
21 X 1
one revolution of gear e. 64.285 X 7 X 3.1416 = 1,413.704
inches. 1,413.704 inches ^ 36 = 39.269 yards, length of lap.
This example could also be expressed as follows:
30_Xi.3_X 7 X 3.1416 ^ 3^ ^e yards
21 X 1 X 36
A constant for the measuring motion may be obtained by
omitting the change gear or considering it a 1-tooth gear.
This constant, multiplied by the number of teeth in any
change gear, will give the length of lap delivered when using
that gear, and consequently the gear for producing a certain
38
PICKERS
17
16
-4'e"
6S 1
■ \
Apron Roll
EvenerRoll
Feed Roll 2V8"Dia.
Beater 1300 R.RM.
Cage
Stripping Roll \:z^i
CalenderRoll
1
76^ S
73
^ =13?
9"Fluled/CalenderRoll
m Draft Gear
37
Fig. 28
§17 PICKERS 39
length may be found by dividing the length of lap required
by the constant. The constant is obtained as follows:
30x (1) X 7 X 3.1416
21 X 1 X 36
= .8726, constant
35. Draft of Intermediate and Flnislier Pickers.
The draft change gears are shown on both plans, Figs. 27
and 28. In the machine shown in Fig. 27, there are two change
gears Wi, //, so that if the proper draft cannot be obtained by
changing one gear, the other may be changed. The draft of
an intermediate picker is usually about 4.25 and that of a fin-
isher picker about 4.50, when there are 4 laps up at the back.
The total draft of the machine shown in Fig. 27, with a gear
of 55 teeth on the lower-cone shaft meshing with a gear of
35 teeth, and wath the belt in the center of the cones, is
as follows:
9 X 24 X 12 X.17 X 18 X 27 X 55 X 9 X 78 X 24 ^ ^ ^^^ ^^^^^
24 X 53 X 96 X 60 X 27 X 35 X 9 X 2 X 12 X 3
The total draft of the machine shown in Fig. 28, with a
20-draft gear and the belt in the center of the cones, is as
follows:
9 X 18 X 14 X 14 X 30 X 54 X 3.25 X 85 X 28 X 12
37 X 73 X 76 X 20 X 40 X 10 X 1 X 20 X 16 X 2i
draft
= 4.275,
CARE OF PICKERS
36. Regulation of Air-Current. — The air-current that
draws the cotton to the cages should be regulated to draw
the cotton to them in such proportions that the upper cage
w^ill receive an amount slightly in excess of that which the
bottom one receives, since, if the stock is drawn to the cages
in equal amounts, the sheet delivered at the front of the
picker will be formed of two layers of practically the same
thickness, and when run through the next machine, will be
liable to split. Pickers are constructed with dampers in
the flue so that the required adjustments may be made.
The making of a good lap is an important point. It should
be perfectly cylindrical when removed from the machine,
40 PICKERS §17
and should feel as firm at one point as at another. It should
be built so that the layers will unroll easily at the next proc-
ess without sticking- together. This defect, which is known
as splitting, or licking:, is due to various causes; such as
excessive fan speed, improper division of the air-currents,
oil dropping on the cotton, etc.
If the air-current is stronger on one side than on the other,
the side having the weaker current is usually soft. The
velocity of the air-current is also responsible for the amount
of waste removed. If the air-current is too strong, it prevents
good cotton from being struck through the bars, but at the
same time prevents all the dirt from being removed, since
the current is strong enough to carry it forwards. On the other
hand, if the current is so weak that the dirt drops readily,
good cotton may also drop with it, causing excessive waste.
A medium air-current must therefore be found that will allow
the removal of the greatest amount of dirt with the least
amount of cotton. The setting of the grid bars also aids in
this, and the matter of keeping all the parts clean cannot receive
too much attention. In some cases it is found necessary, in
order to avoid an excessive amount of air entering through
the grid bars and preventing the removal of the dirt, to
admit air through the ends of the beater cover or through the
casing that extends over the passage between the beater and
the cages.
The laps delivered should be as near a uniform weight as
possible. Each lap from the finisher picker is usually
weighed, and a variation of i pound in either direction is
allowed; that is, if laps weighing 35 pounds are delivered
when they are the correct weight per yard, any laps weigh-
ing between 341 and 352 pounds are allowed to pass. Laps
weighing outside this range should be put back and run over
again, and if too many of these laps are uniformly heavy or
light, the regulating screw on the evener should be adjusted.
37. Causes of Uneven Tjaps. — When laps are found to
be weighing unevenly, the fault may be at several places.
The feeder may be feeding unevenly; the evener, either on
§17
PICKERS
41
the intermediate or finisher lapper, may be out of order,
possibly through not being cleaned and oiled properly or
through using a stiflE evener driving belt. This should be
perfectly pliable and have good piecings. Cotton may also
remain in the trunks or over the inclined cleaning bars
because these are not kept clean.
Another cause for uneven laps is often found in the posi-
tion of the cone belt on the cones of the evener motion. If,
when the proper amount of cotton is passing through the
picker, the cone belt is running at one end of the cones, it
will not allow the belt to be shifted far enough toward the
nearest end of the cones to correct any considerable varia-
tion requiring a movement of the belt in that direction. The
different parts of the evener motion should be so adjusted
that the belt will run at the center of the cones when the
correct amount of cotton is passing through the machine.
This will give the cone belt one-half of the cones to work on
for regulating either light or heavy laps.
Below is given a table showing for what numbers of yarn
certain weights of lap are generally used:
Numbers
-)f Yarn
Weight of Lap per Yard
From Finisher Picker
Ounces
IS
to
lOS
14.0
IDS
to
20s
13-5
20S
to
30s
13.0
30s
to
40s
12.0
40s
to
50S
II-5
50s
to
60s
I i.o
60s
to
70s
1 1.0
70s
to
80s
1 1.0
80s
to
90s
10.
90s
to
lOOS
10.
lOOS
to
I20S
9-5
I20S
to
I5OS
9.0
42 PICKERS §17
A good production for an intermediate or finisher picker
is about 12,500 pounds per week, allowing from 6 to 10 hours
for stoppages. A finisher picker for making 40-inch laps
occupies a floor space of about 16 feet by 6 feet 82 inches
and requires about 4 horsepower to drive it.
38. Cleaning and Oiling:. — Pickers should be kept
well cleaned and oiled. All oil holes, wherever possible,
should be covered in order to keep grit and sand from the
bearings. In oiling, care should be taken not to allow the
oil to get on the inside of the casings where the cotton
passes. The beater, grid bars, inclined cleaning bars, and
cages should be picked clean of cotton daily and kept free
from dirt and oil. All air passages and pipes from fans
should be kept clean, but the covers of the doors of these air
passages or pipes should not be removed while the machine
is running.
COTTON CARDS
(PART 1)
INTRODUCTION
1. The lap of cotton as it leaves the picker consists of
cotton fibers crossed in all directions, together with a small
amount of foreign matter, consisting more especially of
lighter impurities such as pieces of leaf, seed, or stalk, and
thin membranes from the cotton boll. Such material is of
too light a nature to be removed by the action of the beaters
or to drop through between the grid or inclined cleaning
bars of the pickers, so that it is carried forwards with the
cotton and into the lap. In order to remove this foreign
matter, machinery of an entirely diiTerent character from the
cleaning machinery previously used must be adopted, and
for this purpose the cotton card is employed, the process
being known as carding:- .Carding is regarded by many
manufacturers as one of the most important processes in
cotton-yarn preparation. In addition to cleaning the cotton,
it is also the first step in the series of attenuating processes,
which gradually reduce the weight of cotton per unit of
length sufficiently to form a thread. The lap from the
picker is comparatively heavy, and must be reduced consid-
erably in weight at various machines in order to give the
weight per unit of length required in the j^arn. The carding
process is the one that follows the picking operations in all
cotton mills, whether coarse or fine, and whether making
carded or combed yarns.
2. Objects of CardinjT. — The objects of carding are:
(1) The disentangling of the cotton fibers, or the separation
For notice of copyright, see page immediately following the title page
2 COTTON CARDS §18
of the bunches, or tufts, of fiber into individual fibers, and the
commencement of their parallelization; (2) the removal of
the smaller and lighter impurities; (3) changing the forma-
tion of cotton from a lap to a sliver, accompanied by the
reduction of the weight per yard of the material. A sliver
is a round, loose strand of cotton without, or almost without,
twist, and usually from 40 to 80 grains per yard in weight.
It is generally coiled in a can, and is made at the carding,
drawing, and combing processes.
3. Principles of Carding. — In order to arrive at the
previously mentioned objects, the principle of combing the
fibers between sets of closely arranged wire teeth is adopted;
one set may be fixed and the other moving, or each set may
be moving in the opposite direction to the other, or both
may be moving in the same direction but at different speeds.
In any case, the sets of wire teeth are in close proximity to
one another. The first and second objects — the disentan-
gling of the cotton fibers and the removal of the impuri-
ties — are attained by this means, as the fibers forming the
small tufts are drawn apart and the lighter impurities
are caught between the wires, where they remain until
removed by special means. Use is also made of the cen-
trifugal force of a cylinder covered with wire teeth and
revolving at a high speed in attaining the first and second
objects of carding; the ends of the fibers are thrown against
stationary or moving points of wire and the fibers thus
combed out, while heavier impurities such as sand, dirt, and
dust are thrown out, owing to the high speed of the cylinder.
Another method of arriving at the second object is that
of arranging knives or bars partly around the revolving
portions of the card, to clean and throw off the dirt, sand,
and dust from the fibers as they are drawn past such
obstructions. The third object is attained by adopting the
principle of drafting, the attenuation of the material being
produced by revolving cylinders covered with wire teeth,
instead of by the usual method of rolls, which are used in
this machine only at the feed and delivery.
§18 COTTON CARDS 3
Carding is really a combing or brushing action, the fibers
being operated on by a series of wire teeth, which has the
same effect as loosely holding a few fibers at a time and
striking them with a comb; the process, however, must not
be confused with that technically known as combing, which is
an entirely separate process and used only in the manufac-
ture of fine yarns. The machine employed in carding is
usually spoken of as a card, or sometimes as a cardi?ig
engine; this latter name, however, is used more commonly in'
England than in the United States.
CARD CONSTRUCTION
THE REVOLVING-TOP FLAT CARD
PRINCIPAL PARTS
4. The card that is most commonly used and now
almost universally adopted for new cotton mills is known as
the i-evolving-top flat card, sometimes spoken of as the
revolving Hat card, or the English card. Views of it are
shown in Figs. 1 and 2, Fig. 1 showing one side of the card,
with the machine in condition for operation, while Fig. 2
shows the other side as it is seen when stopped and without
any stock passing through. A section through the same
card from back to front is shown in Fig. 3. The various
parts of the card are lettered the same in all three figures,
and reference letters should be referred to on Fig. 3 espe-
cially; but it is also advisable to refer to Figs. 1 and 2 for
the same parts, in order to identify them and ascertain their
relations to one another. The same letters are used in other
figures throughout this Section in accordance with the follow-
ing list. All parts of a single motion or section of the card
are designated by the same letter, which in some instances is
followed by a figure, known as the subscript, to distinguish
the particular part for which it is used from related parts
having the same reference letter.
COTTON CARDS
§18
IS
COTTON CARDS
MJ
§18
COTTON CARDS
5.
The principal parts 6f the machine are as follows:
a, Lap roll.
rto, Lap that is being carded.
a«, vSpare lap.
rte, Lap plates.
b, Feed-plate.
^,, Feed-roll.
^3, Weights for feed-roll.
c, Licker.
r,, Licker screen.
d, di, Mote knives.
e, Cylinder.
c^, Back knife plate.
^s, Cylinder screen.
Cn, Lower front plate.
fg, Door at front of cylinder.
f,,, Front knife plate.
r,j, Tight pulley on cylinder.
^,3, Loose pulley on cylinder.
/, Flats.
g. Arches of card.
h. Flexible bend on which a
//,, //s, //s, Pulleys for support-
ing flats.
y, Flat-stripping comb.
k, Flat-stripping brush.
/(",, Hackle comb for cleaning
flat stripping brush.
/, Card sides.
/,, Cross-girts.
/-, Doors in frame of card.
ni, Doffer.
;;z4, Doffer bonnet.
jUa, Barrow gear.
wzjs, Side shaft.
n, Doffer comb.
o, Trumpet.
<7,, Top calender roll.
^2, Bottom calender roll.
0^, Can in which sliver is
coiled.
p. Cover of coiler.
/>i, Coiler calender rolls.
portion of the flats rests.
Figs. 4 and 5 show a revolving flat card of another style
of construction, but all essential parts are the same and are
lettered as in Figs. 1, 2, and 3.
6. Feed-Roll and Feed-Plate. — At the back of the
card in Fig. 1 is shown the lap «,, which has a rod a^ passed
through its center and rests on the lap roll a, shown in Fig. 3.
The lap a^ is the one being carded, a spare lap «< being shown
above it in Fig. 1, resting in a s.and a^,. The lap roll a is
constructed of wood and is either fluted or has a rough sur-
face, sometimes produced by covering it with a coat of paint
mixed with sand, in order to cause the lap to unroll by friction
with the lap roll and without any slippage.
The cotton is drawn over the feed-plate b. Fig. 3, by the
feed-roll b^, the single layer, or sheet, leaving the lap at the
COTTON CARDS
§18
§18
COTTON CARDS
9
point rts. As it passes from the lap to the feed-roll, each
outer edge of the sheet comes in contact with a lap guide — a
wedge-shaped piece of metal bolted on the inside of the
plate ae. This guide turns up the edges of the sheet to a
small extent, making it slightly narrower as it approaches
the feed-roll. This tends to prevent the outer edge of the
10
COTTON CARDS
18
cotton from spreading and producing a ragged edge. The
feed-plate b extends under the feed-roll b^, with its nose pro-
jecting upwards in front of the feed-roll almost to the teeth
shown on the circumference of the licker c. The feed-roll b^,
which revolves in the direction indicated by the arrow, is
fluted longitudinally and is sufficiently large in diameter to
resist any tendency to spring or bend when a thick piece of
cotton passes beneath it. Its ends rest in slides and it is
weighted at each end by means of a weight b:,. Figs. 1 and 2,
on a lever that has, as a fulcrum, a lug on the feed-plate.
The lever has a bearing on a bushing on the feed-roll and
thus produces the pressure of the feed-roll on the sheet of
cotton on the feed-plate,
the extent qf which may
be regulated by moving
the weight b^ along the
lever. If the pressure
is too light, the action
of the licker will pull the
cotton from the feed-
roll before it should
be delivered. This is
known as plucking, and
results in cotton being
taken by the licker in
large and tangled flakes
that have not been
Fig. 6 , , .
opened, thus causmg un-
even work and requiring the finer parts of the card to perform
the heavy work, which should be done by the licker.
Above the feed-roll rests a small iron rod b. that is revolved
by frictional contact with this roll and, since it is covered
with flannel, collects any fiber or dirt that may be carried
upwards over the surface of the feed-roll and thus acts as a
clearer. It also serves to prevent any air-current from pass-
ing between the feed-roll and the licker cover.
The lap roll a is positively geared with the feed-roll /', in
such a manner that the feed-roll takes up exactly the amount
§18
COTTON CARDS
11
of cotton delivered by the lap roll, without any strain or
sagging, and as it revolves, carries this cotton over the nose
of the feed-plate so that a fringe is brought under the action
of the licker c in the man-
ner shown in Fig. 3, and
on a larger scale in
Figs. 6, 7, 8, and 12. The
upper end of the nose of
the feed-plate is rounded
so as not to damage the
cotton resting on it and
pressed against it by the
action of the licker.
7. The important dif-
ference in various feed-
plates is in the distance
from the bite of the feed-
FlG.
roll to the lower end of the face, indicated by the arrow in
Figs. 6, 7, and 8. By regulating this distance in accordance
with the length of staple being worked, the entire length of
staple is so supported that
it receives the full benefit
of the cleaning and dis-
entangling action of the
licker, which reduces the
work on the finer parts of
the card. The distance
between the bite of the
feed-roll and the lower
edge of the face of the
feed-plate should be from
-\t to i inch longer than
the average length of the
cotton being worked, as
it is necessary that the
fibers should be free from the bite of the feed-roll before the
action of the teeth of the licker exerts its greatest pull, which
Fig. 8
12
COTTON CARDS
§18
Fig. 9
is at the lower edge of the plate; otherwise, the fibers would
be broken. The fringe of cotton is shown in Fig. 9. The
feed-plate shown in
Fig. 6 is suitable for
sea-island cotton, as
it has a face that
makes it possible for
the long fibers to
hang down; the feed-
plate shown in Fig. 7
is the style common-
ly used in America,
being adapted for
the various grades
of American and
Egyptian cottons.
A feed-plate with a
shorter face, as
shown in Fig. 8, is sometimes made for very short-stapled
cottons, such as those grown
in India and China.
8. Two-Roll Method of
Feeding. — Some cards, in-
stead of having the feed-
roll and feed-plate, are con-
structed so as to feed the
licker by means of two feed-
rolls, as shown in Fig. 10.
This is an older form of
feeding and is not so desir-
able. The disadvantage of
this method is that a fourth
of the diameter of the
lower feed-roll is covered
with loose cotton before it
reaches the point where it comes under the action of the
teeth of the licker, thus tending to increase the possibility
Fig. 10
§18
COTTON CARDS
13
of the licker plucking large tufts of cotton before the cotton
ought to be delivered. This system is also inferior on
account of the brief opportunity given for the licker to
operate on the fringe of cotton, as compared with the roll
and feed-plate system, where a long fringe of cotton is
presented to the licker, thus giving a much better oppor-
tunity for combing and removing the dirt. In fact, the
combed fringe of cotton in a card using the feed-plate
can be arranged to be about three times the length of that
in a card using the two-roll method of feeding.
9. Licker. — The object of either of these feeds is to
feed a regular supply of cotton to the licker c, shown in
=ls
'//.
'i
(c)
Fig. 11
Fig. 3, sometimes called the leader, taker-i7i, or licker-in.
The licker consists of a hollow metal roll about 9 inches in
diameter. On the outside of the shell, or curved part, of the
roll, and extending from one end to the other, are spiral
grooves into which rows of teeth are inserted. Fig. 11 {a)
is a view of the teeth of the licker as they appear when
looked at from above, and also shows the fibers being carried
by them from the feed-roll, thus indicating the manner in
which the lap of cotton is separated almost into individual
fibers by the operation of the licker, which revolves so
rapidly, compared with the amount of cotton delivered,
that about 2,000,000 teeth pass the nose of the feed-
plate while 1 inch of cotton is being delivered. It will be
14 COTTON CARDS §18
seen from Fig. 11 (a) that the teeth are scattered, or
staggered, over the shell of the roll in consequence of the
spiral arrang-ement, and thus one tooth does not strike
the fringe of cotton exactly where the previous one struck.
Fig. 11 (r) is a section of a portion of a licker showing
.the construction of the wire from which the teeth are formed,
and also the method of fastening it securely in the roll.
The teeth are punched out of a narrow, fiat, strip of steel, or
wire, carrying a thickened rib along one edge. This rib is
forced into the grooves prepared in the shell of the licker,
and the teeth project, as shown in Fig. 11 {b) , the dotted
line indicating the depth to which the rib is sunk into the
shell of the licker. Several separate spirals are laid side by
side, the distance between two rounds of any one spiral
being 1 inch, and there are either five, six, seven, eight,
nine, or ten spirals side by side, according to the class of
work for which the card is intended. This results in the
distance between the centers of two consecutive spirals
being either i, i, t, i, i, or -iV inch apart, while the points
of the teeth are usually \ inch apart lengthwise of the wire.
The shell of the licker c is shown in section in Figs. 3
and 12, which also show the relative position of the licker to
the contiguous portions of the card. Below the feed-roll b^,
clearer b.,, and feed-plate b are seen the sections of two
knives d,dy, which are known as mote knives. These
knives extend across the card in the position shown, with
the blade of the knife near the teeth of the licker; their
object is to remove such impurities as hulls, husks, bearded
motes, etc., or in other words, all portions of matter other
than cotton.
At the nose of the feed-plate, the licker is moving in a
downward direction and the teeth are pointing in the direc-
tion of its revolution. Since the fringe of cotton is held by
the roll, it will be disentangled as the teeth pass through it.
When the cotton is released from the bite of the feed-roll,
it will be taken by the teeth of the licker. Any short fibers,
however, that are not sufficiently long to be secured by the
licker, will fall through the space between the mote knives.
§18
COTTON CARDS
15
The cotton that drops in this manner is known as fly, and
its loss is beneficial since it leaves the cotton that passes
forwards in a more uniform condition as regards its length
of staple. The licker has a surface speed of about 1,000 feet
per minute, and thus, as it revolves with the cotton, the
portions of the fibers that are not in contact with the teeth
will be thrown out by centrifugal force, so that the impurities
that project from the fibers on the surface of the licker will
come in contact with the blades of the mote knives and be
removed, dropping into the cavity below the knives.
In the usual construction of cards there are two of these
mote knives, although one may be used. The knives are
rigidly held in suitable supports, and in the style under
consideration their correct angle is decided by the machine
builder, the arrangement being such that this angle cannot
be changed. They are sometimes, however, made adjustable,
either by being placed in a swinging frame or, as in Fig. 12,
by being provided with setscrews iL, and locknuts ^Z,, by
16 COTTON CARDS §18
means of which either knife may be moved closer to or
farther from the Hcker and then locked in position; or the
entire bracket d^ that carries both knives, may be moved
farther from or closer to the feed-plate by loosening the
screw d^, sliding the entire bracket d^ on the frame of the
licker screen, and then relocking it.
10. Licker Screen and Licker Cover. — Underneath
the licker is a casing Cx known as the licker screen. This
casing, which is shown in Figs. 3 and 12, is made of tin and
extends across the card. The portion of the screen directly
under the licker is composed of transverse bars r,, triangular
in shape with rounded corners and set with their bases
inverted, the remainder of the screen being plain metal. As
the licker revolves, whatever heavy impurities were not
previously taken out will be thrown through the openings in
the screen, due to the action of centrifugal force. The cotton
will also come in contact with the screen as it did with the
mote knives, and thus additional impurities will be removed.
The top of the licker is protected by a metal cover c^
known as the licker cover", or bonnet, which is curved to
correspond to the curved surface of the licker. This cover
is held in position by two disks, one at each end, through
which the shaft of the licker projects. These disks are held
in position by flanges attached to them, which rest in the
licker bearings attached to the framework of the card. The
licker cover is screwed to these disks, and thus the licker is
completely enclosed. The points where the shaft passes
through the disks should be kept clean and well oiled; other-
wise, the points of contact will become heated and tend to
bind the shaft.
11. Card Cylinders. — Situated about midway between
the back and front of the card, and a prominent feature in its
construction, is the cylinders, mounted on the shafts,. This
cylinder is usually 50 inches in diameter, while its width
depends on the width of the card, being usually 36, 40, or
45 inches. Formerly card cylinders were made of wood, but
it is now the universal practice to construct them of cast iron,
§18 COTTON CARDS 17
as metal resists the changes of temperature and humidity-
better than wood, which is Hable to warp and twist and thus
prevent accurate setting of the card. When metal cylinders
were first used, the shell ^,, Fig. 3, was constructed in two
pieces, which were bolted together, but the best and most
modern method is to make the shell in one casting, with a
sufficient number of longitudinal and sectional ribs on the
interior of the shell to make it strong and rigid. This shell
is mounted at each end on a spider e^, which consists of a
heavy rim cast in one piece with a series of strong supporting
arms. The hubs of the spiders are accurately bored for the
reception of the shaft of the cylinder, while the rims are
turned to a true shape and size and accurately fitted to the
ends of the shell.
The cylinder should be mounted on its shaft as rigidly as
possible, to avoid the possibility of its becoming loose. The
method adopted in the card under consideration is as follows:
A shaft long enough to pass through the shell and project
sufficiently beyond to rest in the bearings and also carry the
necessary pulleys for driving the cylinder and various parts
of the card is forced into its position through the hub of each
of the spiders by means of a powerful screw press. It is then
secured to the spiders by means of two large taper dowels,
one at each end of the cylinder. These dowels are driven
into holes drilled through the hubs of the spiders and through
the shaft.
The complete cylinder should be turned and afterwards
ground while resting on its own bearing, not on a mandrel,
so as to produce an absolutely true surface when in opera-
tion. As these cylinders are intended to run at a high speed,
they are also balanced so as to insure even running, and
when their construction is complete the ends are cased in
with sheet iron to prevent dust or fiber from entering the
cylinder and to avoid accidents that would be liable to result
if they were rotated at a high speed with uncovered arms.
In Figs. 1 and 2, the letter e applies more directly to these
end casings, although it is used to indicate the cylinder
as a whole.
18 COTTON CARDS §18
THe surface of this cylinder is covered with card clothing,
which is a fabric with teeth embedded in it and projecting
through it at an angle. The addition of the clothing to the
cylinder increases its diameter to about 50f inches. Refer-
ence to Fig. 3 shows the teeth on the surface of this cylinder
pointing in the direction of its motion, as indicated by the
arrow shown on the shell of the cylinder. A point on the
surface of the cylinder travels about 2,150 feet per minute.
The teeth of the wire are set very closely in the fabric, there
being about 72,000 points to the square foot and more than
3,000,000 points on the entire cylinder. A fuller description
of this clothing, together with the manner in which it is
applied, is given later.
12. The description of the licker and its operation on
the cotton has been carried far enough to explain how the
heavier impurities are removed from the fringe of cotton
projecting over the feed-plate and driven downwards into 'the
space beneath the card, and also how the fibers are removed
from this fringe when they project downwards sufficiently to
be released and are carried along on the ends of the teeth of
the licker at a speed of about 1,000 feet per minute. These
fibers are now transferred to the surface of the cylinder,
which is rendered possible by the respective directions of
motion of the cylinder and licker and by the direction in
which their teeth are pointing. At the point where the
licker and the cylinder almost come in contact, both are
moving in the same direction and have their teeth pointing
upwards. The teeth on the licker are comparatively coarsely
set, while those on the cylinder are finely set and have a
much greater tendency to hold and to retain the minute fibers
than the teeth of the licker. The cylinder is also revolving
at more than double the surface speed of the licker, and con-
sequently the fibers are swept off the surface of the licker
where the surfaces of the licker and cylinder are in closest
proximity and carried upwards on the surface of the cylinder.
Fig. 13 shows the relative positions and the respective
styles of construction of the licker and the cylinder at the
18
COTTON CARDS
19
point where they approach each other, while Fig. 14 shows
an enlarged view of the teeth.
In Figs. 3 and 18, a metal plate designated as a cover is
shown in connection with the licker
cover. This cover e^, which is
known as the back knife plate,
protects the cylinder at this point
and prevents an air-current from
being formed by the motion of the
cylinder. A wedge-shaped piece
of wood Ct covered with flannel is
usually placed in the receptacle
formed by the junction of the licker
cover with the back knife plate,
in order to prevent any possible
chance of an air-current.
13. Flats. — Above the cylin-
der and partly surrounding its
upper portion is a chain of flats /,
Fig. 13
as shown in Figs. 1, 2, and 3.
These are the parts that give
the name renolvhig-
top flat card to the
card. They are made
of cast iron, approxi-
mately T-shaped in
section, and are part-
ly covered with
card clothing about
\f, inch wide. They
are usually li inches
wide and slightly
longer than the width
of the cylinder, but
are covered with
clothing only over the
portion of their length that corresponds to the width of the
cylinder. This clothing is of a finer wire, with the teeth more
20
COTTON CARDS
§18
closely set, than that on the cylinder, and is usually fastened
to the flat by clips on each side of the flat. There are from
104 to 110 flats on a card, but as they are in proximity to the
cylinder for only about one-third of its circumference, only
from 39 to 43 flats are presented to the cylinder at one time.
Fig. 15 (a) gives an end view of a flat, while (d) shows a
section. Each end is drilled and tapped to receive a set-
screw, which passes through a hollow stud carrying links,
and as each link extends from one flat to the next and each
end of each link encircles
one of these hollow studs,
the flats are connected in
an endless chain. The
screw that is inserted is of
special construction, right-
hand screws being used on
one side of the card and
left-hand screws on the
other, so that the motion
of the flats will tend to
tighten rather than to
loosen the screws and thus
avoid the possibility of
their becoming loose and
allowing a flat to come in
contact with the cylinder,
which would cause con-
siderable damage.
The flats must be so ar-
ranged that they will be supported immediately above the
cylinder without coming in contact with it or without their
supports interfering with its rotation. This is done by
means of two arches ^, Figs. 1 and 2, which are strongly
constructed castings resting on the framework of the card,
one on each side, and securely bolted to it. Each arch
carries five brackets //,, which are composed of several
pieces. One portion of each bracket projects upwards suf-
ficiently to carry a pulley that serves as a support for those
§18 COTTON CARDS 21
flats that are not performing any carding action and that
are passing backwards over the cj^linder, while another
portion of each bracket serves as a support for the flexible
bend // and provides a ready means of adjusting it in order
to move the wire teeth of the flats that are at work nearer to
or farther from the wire teeth on the surface of the cylinder.
A fuller description of the arrangements for adjusting the
flexible bends will be given in the description of setting cards;
it is sufficient to state here that the flexible bends can be
moved farther from, or nearer to, the cylinder shaft at any
one of five setting points on either side of the card, and by
this means the upper edges of the bends can be adjusted so
as to be practically concentric with the circumference, or
wire surface, of the cylinder.
About forty of the flats rest on the flexible bend at each
side of the card; the portions that are in contact with the
Dends are the two surfaces ^ and f^, Figs. 15 and 16. The
chains are placed as near the flexible bends as possible, since
if they are too far away, the pull and weight of the chains
will cause a deflection in the flat. It is absolutely necessary
that the chains on each side shall be exactly alike and work
with the same tension, as the smallest variation will pull the
flats out of their proper positions over the cylinder, and their
accurac}^ will thus be destroyed. Chains are now so made
that the whole variation from the standard is not more than
sV inch. The flats are, of course, linked together on each
side of the card by an exactly similar arrangement, except
that, as has been previously stated, left-hand screws are used
on one side and right-hand screws on the other.
14. Another representation of flats at work is given in
Fig. 16, which shows them resting on the flexible bend, and
held so that the points of the wire on their surfaces are
almost touching the points of the ware on the cylinder. The
exact distance between the wire on the flats and that on the
cylinder is adjustable, and is usually about i i n o inch. The dis-
tance between the wires, however, is not the same at each
point in the width of the flat, as will be seen by referring
22
COTTON CARDS
§18
Fig. 16
to Fig. 16. The wire of the flat at the point /= is closer
to the cylinder than at the point /« in each case. The end
view of the flat in Fig. 15 (a) shows that the metal compos-
ing the flat end is cut away more on the side f, than on the
side /j; consequently, when this flat is turned over and rests
on the flexible bend, the side /, will drop closer to the cylin-
der than the side /j,
and the wires on the
side /s will drop lower
than the wires on the
side /s, thus making a
slightly wedge-shaped
space between the
wires of the flat and
the wires of the cylin-
der. The side /s of the flat, which is nearer to the cylinder,
is known as the heel, while the side that is farther from the
cylinder, namely, /«, is known as the toe. Flats are always
constructed with this heel-and-toe formation, and it should
be preserved throughout the life of the card.
The chain of flats is not stationary, but moves at a very
slow speed, those flats nearest the cylinder moving toward
the front of the card, while of course, the flats that are not
working are carried backwards over the top of those that are
at work. The means of imparting motion to the flats, which
will be described in connection with the gearing of the card,
results in a steady, smooth movement usually at the rate of
about 3 inches per minute, although this may be changed to
either a faster or slower speed, according to whether it is
desired to remove more or less waste, respectively, from the
cotton. The object of giving a movement to the flats is
to carry toward the front of the card those flats that have
become filled with impurities, so that they may be stripped
and brushed out before they become too full of leaf and other
foreign matter to perform the duty of carding the cotton.
15. The method of supporting the flats that are not at
work is shown in Figs. 1, 2, and 3. They are supported at
§18 COTTON CARDS 23
the front by two pulleys /,, one at each end of a shaft that
has its bearings in two brackets, one on each side of the
card. On the same shaft with these two pulleys are two
sprocket gears, the one shown being marked /«, the teeth of
which mesh with the ribs on the back of the flats, and as this
shaft is driven by means of worms and worm-gears, the
sprocket gears drive the flats. The portion of the chain of
flats directly above the cylinder and resting on the flexible
bends revolves in the same direction as the cylinder, namely,
toward the front. The flats that are not at work move back-
wards, in the opposite direction to the cylinder, and rest on
pulleys //j, //s, //g supported by brackets h^ attached to the arch
of the card and duplicated on each side. The ends of the flats
rest on these pulleys and impart motion to them by frictional
contact. Two of these pulleys //« at about the center of
the card are connected by a shaft //,o that extends across the
card. The pulleys lu, which are directly over the licker, form
the turning point of the flats. Those that have been cleaned
and carried along over the top turn and pass over the cylin-
der to perform their work, while those that have just
finished their work, being charged with impurities, pass
around the pulleys at the front and are cleaned. The
bracket //,, which supports the pulley //», is so constructed
that the pulley may be raised or lowered to take out the sag,
or slack, in the chain of flats or to allow sufiflcient slack for
the flats to revolve freely.
16. As previously explained, the cotton is transferred
to the face of the cylinder from the licker at the point where
the two surfaces nearly touch each other, and is carried
upwards and forwards by it until brought to the point where
the flats and cylinder are brought into close proximity.
When the cylinder reaches the first flat, the cotton on its
surface has a tendency to project from it on account of the
centrifugal force of the cylinder, and comes in contact with
the teeth at the toe of the first flat. The stock is gradually
drawn through the teeth of the flat, receiving more and more
of a combing or carding action, until the heel of the flat is
24 COTTON CARDS §18
reached, where the teeth of the flat and the cylinder are in
the closest proximity, and where the cotton consequently
receives the greatest carding action.
Some of the fibers that have not projected sufficiently may
not have received any carding action, and the cylinder carries
them forwards to the next flat. Those fibers that have been
carded once may be carded again, with such additional fibers
as are brought under the action of the succeeding flat, and
so on throughout the entire series. The flats are set a little
closer to the cylinder at the front, or delivery end, than at the
back, or feed, end, of the card, and this method combined with
the heel-and-toe arrangement of the flat insures a gradual and
effective carding of all the fibers before they have passed
under the last flat. The small impurities are left behind,
since they are forced between the teeth of the wire on the
flats or cylinder and remain there until the wire is cleaned, or
stripped, as will be explained later. Thus the short fibers
and impurities are retained, while the long, clean fibers are
passed forwards.
17. Flat-Stripping Combs. — At the front of the card
in Figs. 1, 2, and 3 is shown a comb j supported by two
arms /d/s. This comb consists of a thin sheet of steel
attached to a shaft and having its lower edge made up of fine
teeth. It is capable of adjustment so as to be moved closer
to, or farther from, the wire on the flats. The comb is given
an oscillating motion by means of a cam acting on the arm /a,
Fig. 2, and at each stroke strips from a flat a portion of the
short fiber, leaf, and other impurities that adhere to its face.
With the arrangement shown in Figs. 1 and 2, a close setting
between the comb and flats is not possible owing to the
difficulty in giving a backward movement to the comb with-
out damaging the clothing of the flats.
Fig. 17 {a) represents a method of actuating the comb /
that differs somewhat from that adopted on the card shown
in Figs. 1 and 2. Fig. 17 {b) is a front view of the comby
with bearing jr. and actuating lever /,. This comb has two
motions; namely, an oscillating motion, which it receives
§18
COTTON CARDS
25
through the arm j^ from the cam j^, by letting the arm j^
swing around the point j-, as a fulcrum, and a turning motion
in its bearings 75, received through the lever /« from the
cam y'e. The teeth of the flats / are stripped while they are
pointing downwards by a downward stroke of the comb,
governed by the cam j^. As the comb lifts, it is traveling in
a direction opposite to that in which the teeth are pointing,
and to prevent injury to the wire the comb is turned away
from the flats by means of the cam j^. By the use of this
arrangement, a closer stripping action is obtained without
damaging the wire.
18. Briisli. — After the waste, known as Hat strippings,
has been removed by the comb y, the flats are brushed out
by means of the brush k, shown in Fig. 17 {a) and also in
Figs. 1, 2, and 3. This brush consists of a wooden barrel
around the surface of which bristles are inserted in four spiral
coils, the bristles being long, for a short distance at each end
26 COTTON CARDS §18
in order to brush the ends of the flats, and shorter in the
middle so as to just reach into the wire of the flat clothing.
It is possible to adjust the position of this revolving brush
so as to remove from the flats any impurities that were not
taken out by the comb. The brush after it has operated on
the flats is cleaned by means of a hackle comb /^,, Figs. 1, 2,
and 3, the teeth of which project into the bristles of the brush
and remove impurities. The hackle comb is periodically
cleaned by hand. The flat strippings are either allowed to
fall from the stripping comb on the steel covers m^,e^ or are
collected on a round rod /^,, Fig. 1, which is suspended
directly below the comb and rotated by frictional contact
with the flats, thus collecting the strippings as they fall
from the flats. These strippings, whether allowed to drop
on the steel cover or wound on the surface of the rod, are
removed periodically by hand.
19. Cylinder Screen. — Beneath the cylinder is placed a
screen e^. Fig. 3, known as the cylinder screen. This con-
sists of circular frames on each side of the card, practically
corresponding to the curvature of the cylinder and connected
by triangular cross-bars e^. As shown, the cylinder screen is
constructed in halves, which are held together at e-,. It is so
supported that it may be set closer to, or farther from, the
cylinder, while at the same time it retains practically the same
curvature as the cylinder. As the cylinder revolves, the fibers
that project come in contact with the screens, and thus the
dirt and other foreign substances will be struck off or thrown
through the openings in the screens, and cannot be drawn
back. The screens also aid in preventing the good cotton
from leaving the cylinder. A screen of a similar character
was mentioned as being placed below the licker; the licker
screens and cylinder screens are usually connected so as to
form one complete adjustable undercasing beneath both
licker and cylinder.
20. Card Frame. — The entire mechanism thus far
described is supported on the framework of the card. This
consists of two strong and solid card sides /, which are
§18 . COTTON CARDS 27
connected by cross-girts K with the ends accurately milled
and securely bolted to the card sides, thus forming- a large
rectangular frame. To this is attached a partition /,, Fig. 3,
that separates the dirt and fly produced by the mote knives
from the licker and cylinder fly. In the card under descrip-
tion, this partition only projects downwards for half the
distance between the licker screen and the floor. In some
styles, however, the partition extends down to the floor and
has a door in the center so that access can be obtained to the
rear of the cylinder screen and space below. Around the
framework of the card are doors h that can be removed for
the purpose of removing fly, setting undercasings, or exam-
ining the under parts of the card. There are four of these
doors on each side of the card in addition to one at the front
and one at the back.
21. Doffer. — Directly in front of the cylinder, in Figs. 1,
2, and 3, is seen the dofifer m, which is supported by the
doflfer shaft w, and is constructed on the same principle as the
cylinder. It consists of a perfectly rigid cylindrical shell w,
carried at each end on a spider Wa with six arms, to which it
is firmly secured, the whole being rigidly attached to the
doffer shaft. The doffer is covered with card clothing in a
similar manner to the cylinder, except that the wire on the
doffer is more closely set and somewhat finer. The doffer
is the same width as the cylinder, but is of a much smaller
diameter usually about 24 inches, but sometimes 27 inches.
A large doffer is to be preferred, since it gives the same pro-
duction with a lower speed or a larger surface speed with the
same number of revolutions, and also gives the cylinder a
better chance to deliver the fibers on account of its presenting
a larger wire surface, although the advantage is not very
great in either case. The doffer revolves in the opposite
direction to that of the cylinder, the respective direction of
motion at the place where they most nearly approach one
another being shown by arrows in Fig. 3. At this place also
the teeth of the cylinder and doffer point in opposite direc-
tions. As the teeth of the cylinder point in the direction in
28 COTTON CARDS §18
which it moves and were pointing upwards at the place where
they took the cotton from the licker, they consequently
point downwards at the front of the card, while the teeth of
the dofifer at this place point upwards. The surface speed of
the dofifer, which varies from 44 to 107 feet per minute,
is much less than that of the cylinder. As the cylinder
approaches the doffer its surface is covered with separated
fibers of cotton. Since it is set within about .005 inch
from the doifer and the dofifer is revolving so much more
slowly, the fibers of cotton are deposited by the cylinder on
the face of the doffer. They are condensed considerably
from their arrangement on the surface of the cylinder because
while spread over from 20 to 40 inches on the surface of the
cylinder, they are laid in the space of about 1 inch on the
surface of the doffer. The amount of this condensation varies
according to the relative speed of the cylinder and dofifer.
It does not necessarily follow that all the fibers are taken
from the cylinder by the dofifer the first time the cotton
passes the point where the transfer is made, as they may not
be in the proper position to become attached to the dofifer.
In this case, they may be carried around by the cylinder a
second time and be more efifectively carded. The doffer
may be considered as merely a convenient means of removing
the fiber from the cylinder. It is not intended to have any
cleaning action, as the cleaning on the card is practically
completed when the cotton has passed the fiats, but as a
matter of fact, it does remove some short fiber and light
impurities that adhere within the interstices of the wire.
There is no screen beneath the dofifer, as it is unnecessary,
but placed above it is a protection consisting of a metal
cover m^ known as the doffer bonnet and shown in Figs. 1,
2, and 3, while another view is given in Fig. 18. This
metal cover extends over the upper surface of the dofifer,
protects it from injury, and forms a portion of a receptacle
to hold flat strippings in case no other method of gathering
them is provided. At the point vi^ it extends to, and is
almost in contact with, a plate of steel e^ placed over the
front part of the cylinder that performs the same duty
§18
COTTON CARDS
29
for the cylinder; namely, protecting* it from damage and
forming a part of the receptacle for the fiat strippings.
This plate e^ extends upwards until a loose portion e^ is
reached, which forms a door, the position of which, when
closed, is shown in Fig. 18 in dotted lines. This door swings
on arms r,o so constructed that it can be thrown forwards and
rest on the doffer bonnet; it is shown in this position in
Fig. 18. Immediately above the space formed by the open-
ing of this door is another plate e^, which extends from the
Fig. 18
door up into the space between the flats and the cylinder,
almost in contact with both of them. This platen,, is known
as the front knife plate. It is also the object of these
covers, or plates, mentioned in connection with the cylinder,
doffer, and licker, to guard against accidents to the opera-
tives, the licker being especially dangerous.
A draft strip, or making-up piece, Wg is usually placed in the
recess formed by the doffer bonnet and the plate c», so as to
fit the angle between the doffer and the cylinder and thus
prevent dirt from entering the space between these two
30
COTTON CARDS
18
parts. It also prevents draft and thus does away with fly,
which would otherwise gather and come through in lumps.
22. Doffer Comb. — The cotton is carried around by the
doffer on its under side until it reaches the doffer comb ;/,
Fig. 3, which is directly in front of the doffer and has an
oscillating motion of about 1,800 or 2,000 strokes per minute.
One of the bearings of the comb is an ordinary bearing,
2 ma. P, Pjf.
q-
FiG. 19
while the other is in a box known as the eonib box, which
contains the eccentric that gives the motion to the comb.
The position of these bearings can be altered by adjusting
screws in order to obtain the proper distance between the
comb and the surface of the doffer. The comb, as shown in
Figs. 1, 2, and 3, consists of a thin sheet of steel attached to
a shaft by a number of small arms; its lower edge is com-
posed of fine teeth resembling somewhat the teeth of a fine
§18 COTTON CARDS
31
saw. The teeth of the doffer, which were pointing upwards
when in position to receive the cotton from the cylinder, are
pointing downwards at the point nearest the comb. The
downward strokes of the comb are in the same direction that
the teeth of the doiTer are pointing and in close proximity
to them, thus making the operation of removing the cotton
very easy.
The cotton, when it leaves the doffer, is in the form of a
transparent web of the same width as the doffer. The next
work required of the card is that of reducing the web to a
sliver. This is attained by passing the cotton through a
guide and then through a trumpet o, on the other side of
which are two calender rolls o,, o„ Figs. 1, 3, and 19. The
bottom roll is 4i inches wide and 3 inches in diameter, and
by means of a gear drives the top calender roll, which is self-
weighted, being 4 inches in diameter. The object of these
rolls is to compress the sliver so that it will occupy a com-
paratively small space.
23. Coiler.— From the calender rolls o„o, the cotton
passes through a hole in the cover p of the upright frame-
work, known as the coiler liead, the connections of which
are shown in Fig. 19. It is drawn through the hole in the
cover by two coiler calender rolls, the one shown being
marked/),, which further condense it, and is then delivered
into an inclined tube A on a revolving plate A- The end of
the tube that receives the cotton is in the center of the plate,
directly under the calender rolls />,, while the end of the tube
from which the cotton is delivered is at the outer edge of the
plate p:,. At the bottom of the coiler head is a plate g on
which rests the can that receives the sliver. In consequence
of the sliver being delivered down the rotating tube A, it will
describe a circle and be laid in the can in the form of coils.
The circle described by the bottom of the tube p, is little
more than half the diameter of the can. If the top of the
tube p, were directly over the center of the plate g on which
the can rests and if the can did not turn, causing the laying
of the sliver to depend entirely on the rotation of the coiler
32
COTTON CARDS
§18
tube, the sliver would be placed in a series of ascending
coils, which would have as a center the center of the can,
while the outside edges of the coils would be placed some
distance from the side of the can. The result of this would
be that only a very short length of sliver could be laid in the
can and the coils would become entangled, causing the sliver
to be broken as it was drawn out. In order to overcome this
difficulty the top of the tube p^ is slightly beyond the center
of the plate q, while q is revolving in the opposite direction
to that of the tube p^, but very slowly as compared with the
speed of this tube, p^ making about 26 revolutions to 1 of q.
As a result of this
arrangement each
coil of sliver that is
placed in the can is
in contact with the
side of the can and
no one coil comes
directly above the
preceding coil. A
top view of the sliver
as it appears when
placed in the can in
this manner is shown
in Fig. 20.
The cover for the
coiler head is now
constructed so as to be held in position by a hinge, on which
it can be raised and held open, without breaking the sliver.
This gives an opportunity for inspection and oiling.
Formerly coiler' heads were so constructed that it was
necessary to remove the sliver from the coiler or break the
end of sliver in order to oil the bearings, which necessarily
caused additional waste and loss of production. Occasionally
the sliver breaks and collects within the coiler, causing what
is called a biing-iip.
One feature of the coiler head for the card under descrip-
tion is the use of the swinging calender roll in place of the
§18 COTTON CARDS 33
old-style calender roll, which revolved in fixed bearings and
caused considerable trouble in case of a bung-up in the coiler
head. The calender roll that receives motion from the
upright shaft revolves in fixed bearings, while the other one
is mounted on a swing, or hinge, bearing. The weight of the
roll and bearing is sufficient to keep it in contact with the
fixed roll. It receives motion from the other roll by means of
two spur gears, one on the shaft of the roll revolving in fixed
bearings and the other on the shaft of the swinging roll.
When the coiler tube chokes, the sliver collects around the
top of it and forces the swinging roll up, thus throwing it
out of gear with the fixed roll and preventing any more
cotton from entering the coiler. When a lap forms on either
roll, the increasing diameter of the roll forces up the swing-
ing roll and thus prevents the cotton from winding so firmly
around the roll. This arrangement is also very convenient
because of the fact that the swinging roll can be moved out
of the way in removing the cotton that has lapped around one
of the rolls, thus making it very easy to remove the lap,
whether it has formed on the swinging roll or on the stationary
roll. It also does away with the strain on the bearings and the
necessity of using a knife to cut the lap from the roll, and thus
prevents the surface of the roll from being damaged by the
careless use of a knife.
GEARING
24. In describing the method of driving the different
parts of the card reference will be made to Figs. 21 and 22,
but in order to more fully identify the parts, the plan of the
gearing, Fig. 23, and also those figures that show the parts
of the card assembled, such as Figs. 1 and 2, should be con-
sulted, especially for those parts that cannot well be indicated
on Figs. 21 and 22. Referring first to Fig. 21, which shows
the main driving side of the card, the tight pulley ^„ on the
end of the cylinder shaft receives motion from the driving
belt ^,4, which is driven from the pulley either on the main
shaft or a countershaft of the room. On the other side of
the cylinder, as shown in Fig. 22, is placed a pulley with four
34
COTTON CARDS
§18
separate faces, the face ^,5 carrying- the crossed belt that
drives the pulley c^ on the licker c. Referring again to Fig. 21,
on the other end of the licker is a pulley <:« that drives the
barrow pulley ?;^ by means of a crossed belt. Compounded
vith this pulley is the barrow gear ;;;«, which drives the doffer
gear m^ on the end of the doffer shaft.
Reference should now be made to Fig. 22, which shows
the other side of the doffer. On this side is a bevel gear w,o
§18
COTTON CARDS
35
driving a bevel gear w,. on the side shaft w.^, which carries
at its other end a bevel gear b^ driving a gear l\ on the end
of the feed-roll. On the other end of the feed-roll, as shown
in Fig. 21, is a gear l\ that drives by means of two carrier
gears the lap roll a. Referring again to Fig. 22, the pulley e^s,
by means of the band ;/=, drives the pulley n^, that is com-
pounded with another pulley n^\ this, by means of the band ?^3,
drives a pulley n^ on a short shaft carrying the eccentric that
gives motion to the dofifer comb. A third pulley e^, on the
end of the cylinder shaft, as shown in Fig. 22, drives by
Fig. 22
means of the belt /« the pulley /,„, which is on the same shaft
as the worm /,, gearing into the worm-gear /,2. On the short
shaft with the worm-gear /.^ is a worm /„ driving the worm-
gear /i4, which is mounted on a shaft carrying two sprockets
that gear directly into the ribs on the back of the flats.
The coiler connections are driven as follows, reference
being made to Figs. 19 and 28: The large gear vi^. Fig. 23,
that is on the end of the dol?er and receives motion from
the barrow gear, drives by means of two carrier gears a
gear ^^ on one end of the calender-roll shaft o^. On the
other end of this shaft is a bevel gear o^. Fig. 19, that drives
13 ^ I —
ni-f-
6 Dill
2i''Dia.
9 Dia
r,0 Dhi
24 Dill.
Fig. 23
120
I
t!
16
D
y-
m,3
^Q
o
□
Lmii
40
m„
2 Dia.
§18 COTTON CARDS 37
the bevel gear o^ on an upright shaft. At the upper end of
this upright shaft are two gears, the gear/>5 driving the gear;!'^
on the coiler plate, while the bevel gear p^ drives the bevel
gear p., on the coiler calender-roll shaft. The can table g is
driven by means of a number of gears at the bottom of the
upright shaft and in a rather circuitous manner, which is
rendered necessary in order to obtain the slow motion at
which the can table should travel. The gear g^ is fast to
the upright shaft ^,, while the gears g^, g^ are loose on the
same shaft but compounded by means of a sleeve. The
gear g^ drives the gear g^, which is compounded with
the gear g^, both gears working loosely on a short upright
stud. The gear g^ drives the gear g^, and since g^ and g^ are
compounded, the gear g^ on the can table will receive motion
through the carrier g,.
25. When it is desired to stop the card from delivering
the cotton and yet not break down the end at the coiler, the
catch h, Fig. 24, is released. This figure shows one method
of driving a doflfer; it will be seen that as the feed-roll, calen-
der roll, and all coiler connections are driven from the dof-
fer, they will stop when the catch U is released, throwing the
gear w, out of contact with the doffer gear w^. By this
method it is a simple matter to stop the delivery of the cot-
ton very suddenly if necessary and at the same time allow
the swiftly revolving parts, such as the cylinder and licker, to
remain in motion. Another advantage of this arrangement
is that no waste results when the delivery is stopped. When
the gear vu is again meshed with the gear m^, the portion of
the doflfer that was presented to the cylinder when the dof-
fer was stopped will contain an excessive amount of cotton.
This excess will cause a thick or uneven place in the sliver,
which should be removed. This arrangement is sometimes
called the barrow motion, and the gear We the barrow gear.
The gear w, is usually a change gear, so that the doflfer
may be driven at any required speed, as the production of
the card depends on the speed of the doflfer. In decreasing
or increasing the speed of the doflfer by changing the
38
COTTON CARDS
§18
^18 COTTON CARDS 39
gear m^, the draft of the card and, consequently, the weight
of the sliver delivered, are not affected, since the feed-rolls,
lap roll, and all coiler connections receive motion from the
dofTer and therefore have the same relative speed, whether
Ws is a large or a small gear.
Another method of stopping the delivery of the cotton
without breaking down the end at the coiler is to break the
connection at the doffer by moving the side shaft w,„
Figs. 22 and 23, and also break the connection between the
doffer and calender rolls by turning the handle on the carrier
gear w,3, Fig. 24. The shaft w.. carries a gear at each end,
the gear b, driving the gear b, that is on the end of the feed-
roll, while the gear w„ receives motion from the gear w,„ on
the end of the doflfer shaft. By means of the movable bear-
ing ?;/,^, it is possible to move the shaft w,, outwards at its
front end and thereby disconnect the gears w,„, w„ and
thus stop the feed, while by throwing out the gear m,^ the
calender rolls are stopped, thus allowing the cotton that is on
the dofifer to fall between the doffer and the calender rolls.
This method of stopping the delivery of cotton by the
card allows the doflfer to run without making an uneven
and cut sliver when restarting.
SPEED CALCULATIONS
26. If the driving shaft makes 340 revolutions per min-
ute and carries a 10-inch pulley, the pulley <?.„ Figs. 21 and
23, which is 20 inches in diameter, will be driven as follows:
340x10 ,„^
20 = I'O revolutions per mmute
As the cylinder is 50f inches in diameter, allowing | inch
for clothing, its surface speed will therefore be as follows:
170x501x3.1416 o o-q ^-o x
T^ = z,Joo.b/y feet per minute
27. Licker.— On the end of the cylinder opposite that
of the pulley r,, is the pulley ^,s. Figs. 22 and 23, which is
connected to the pulley c^ by means of a cross-belt and thus
40 COTTON CARDS §18
drives the Hcker. The diameter of if, 5 is 18 inches and that
of Cs is 7 inches, so that when the cyhnder makes 170 revolu-
tions per minute, the revolutions per minute made by the
licker will be as follows:
— — = 437.142 revolutions per minute
7
As the licker is usually 9 inches in diameter, its surface
speed will be as follows:
437.142 X 9 X 3.141 6 ^ 29.993 feet per minute
12
28. Doffer.— The 4-inch pulley c^, Figs. 21 and 23, on
the end of the licker drives the 18-inch barrow pulley m,,
which is compounded with the doffer change gear nis. This
gear, for the purpose of calculation, will be assumed to have
22 teeth; the gear on the end of the doffer contains 190 teeth.
With the licker making 437.142 revolutions per minute, the
speed of the doffer will be as follows:
437.142 X 4x 22 n oiq w
~ — — — = 11.248 revolutions per mmute
18 X 190
As the doffer is 24-f inches in diameter, allowing I inch
for clothing, its surface speed will be as follows:
11.248 X 241 X 3.1416 -o cqw .
— ^-^ = < 2.881 feet per mmute
12
On some cards there is an arrangement for driving the
doffer at two different speeds, the slow speed being used
when piecing up an end. One method of construction for
driving at different speeds is to have two pulleys of different
sizes on the licker shaft and to have two belts extending
to W7. At 7)1. there are three pulleys, the center pulley being
loose, while the other two are fastened to the shaft; conse-
quently, when one belt is on the loose pulley, the other is
on one of the fastened pulleys. The belts are shifted by
means of a shipper handle.
29. Flats. — With the cylinder making 170 revolutions
per minute; diameter of e^, Figs. 22 and 23, 5 inches;
diameter of /,„, 10 inches; /,i, single-threaded worm; /,„
§18 COTTON CARDS 41
16 teeth; /„, single-threaded worm; /„, 42 teeth; and diam-
eter of pulley driving- flats, 8 inches; the speed of the flats will
be as follows:
170_X5X1X1X8X3^16 ^ 3^79 .^^^^^ ^.^^^^
10 X 16 X 42
30. Draft. — The following examples illustrate the man-
ner of finding the draft:
Example 1. — Find the draft between the lap roll and feed-roll,
referring to Fig. 23 for data.
2 5 X 48
Solution. — ^ — v^^ = 1.176, draft. Ans.
b X 1/
Example 2. — Find the draft between the feed-roll and doflfer, using
a 16 change gear at d^.
^ 24 X 40 X 120 ^o A u a
Solution.- ^ ^ ^q ^ ^^ - '2, draft. Ans.
Example 3. — Find the draft between the dofifer and bottom cal-
ender roll.
„ 3X 190 , ^., , ,, .
Solution. — -- — 7- = 1.13, draft. Ans.
*-4: X — I
ExAMPLE 4. — Find the draft between the bottom calender roll and
coiler calender rolls, referring to Fig. 19 for data.
2 X 24 X 18 X 27 , n-o ^ .. a
Solution.- 3 ^ 24 x 18 X 1 7 = ^■^'^' '^'^^'- ^°^-
Example 5. — Find the total draft of the card shown in Fig. 23,
figuring from the coiler calender rolls />,, Figs. 19 and 23, to the lap
roll a, Figs. 21 and 23, and using a 16 change gear at d^.
„ 2X24X18X27X190X40X120X48 ,^,,00^ r.
Solution.- -6^ x24X18X17x21X40X16x17 = 101-433. draft.
Ans.
Proof. — To prove that intermediate drafts equal total
draft, 1.176 X 72 X 1.130 X 1.059 = 101.325.
31. Waste. — In the passage of the cotton through the
card there are several places where waste is made. There is
a certain amount under the licker and the cylinder, and also
between the wires of the clothing on the flats, cylinder, and
doffer. This amount of waste should not as a rule exceed
5 per cent., and the work of the card should be closely
watched, especially with regard to the waste under the
42
COTTON CARDS
18
cylinder, which should be examined at frequent intervals to
see if it contains too much good cotton.
32. Prodviction. — The production of the card varies
according to the class of work, a good production on low
numbers being from 700 to 1,000 pounds per week, while
for fine yarns it is much lower. The weights of delivered
sliver suitable for certain classes of work are as follows:
Variety of Cotton
1
Numbers
Weight per Yard
Grains
IS to IDS
70
IDS to 15s
65
Average American ...
15s to 20s
60
20s to 30s
55
30s to 40s
50
1 40s to 60s
50
Allan-seed and Peelers . ■
60s to 70s
45
70s to IOCS
40
40s to 60s
55
Egyptian "
60s to 70s
50
70s to lOOS
45
Sea-Island
70s to IOCS
loos upwards
35
30
33. Wei§:ht and Horsepower. — The weight of a single
revolving flat card is about 5,000 pounds. It requires from
I to 1 horsepower to drive it after the initial strain of start-
ing, which requires much greater power.
34. Uimensions. — A 40-inch revolving flat card with a
24-inch doffer occupies a space about 9 feet Hi inches by
5 feet 4 inches. Extra allowance must be made for the diam-
eter of the lap. When the doffer is 45 inches wide, 5 inches
must be added to the width in the above dimensions, while
3 inches must be added to the length when the doffer is
27 inches in diameter.
COTTON CARDS
(PART 2)
FORMER METHODS OF CARD
CONSTRUCTION
1. While the machine described in Cotto7i Cards, Part 1,
is the one that is now almost universally adopted for cotton
carding, it does not by any means adequately represent the
different methods of carding that are, or have been, used.
The method of carding cotton before the era of machinery
was by means of hand cards, which consisted merely of pieces
of wood about 12 inches long and 5 inches wide to which a
handle was attached. A piece of leather through which a
number of iron wires had been driven was attached to the
surface of the board and two of these hand cards were used,
the operator holding one in each hand. The cotton, after
being picked and cleaned, was spread on one of these cards,
and the other was used to brush, scrape, or comb it until the
fibers of cotton lay comparatively parallel to one another.
From this were obtained soft fleecy rolls about 12 inches
long and f inch in diameter, called cardings. These cardings
were pieced together and spun on the hand spinning wheel.
Later developments resulted in the introduction of the
principle of carding by means of a cylinder carrying wire
teeth operating against a stationary framework carrying wire
teeth, this being the first style of mechanical card. From
this was ultimately developed a card used very largely in
America under the name of stationary-top flat card, and to a
limited extent in Europe, under the name of the Wellman
card. This stationary-top flat card was used in almost every
For notice of copyri^hl. see page immediately following the title page
219
2 COTTON CARDS §19
American cotton mill until within the last 10 years, and is
still used occasionally.
The most popular style of card in Europe prior to the
development of the revolving-top flat card was that known
as the roller-and-clearer card, sometimes called the worker-and-
stripper card. This roller-and-clearer card was constructed
with either one or two cylinders, being known respectively
as a single or a double card. Sometimes a combination card
was built with rollers and clearers on the back cylinder and
flats on the front; combination cards have also been built
with single cylinders having flats at the front and rollers and
clearers behind. For special purposes cards have been built
with three cylinders. The system of carding cotton by
rollers and clearers, or workers and strippers, somewhat
resembles the methods now in use for carding purposes in
the woolen industry.
Owing to the world-wide tendency now to adopt the revolv-
ing-top flat card in the cotton industry, considerable space
has been devoted to thoroughly describing that style of
construction, but as there are still in use a number of station-
ary-top flat cards and also a number of the roller-and-clearer
cards, a brief description of each of these styles of construc-
tion will be given.
STATIONARY-TOP FliAT CARD
2. The stationary-top flat card, shown in Fig. 1, is a
smaller and less substantial machine than the revolving-top
flat card, but is very similar to it in the principle of carding
the cotton, differing mainly in the method of stripping the
flats. The machine consists of the usual framework sup-
porting the cylinder and doffer together with the various
parts common to all cards, while above the cylinder are
placed a number of flats. In the older cards these are con-
structed of wood, as shown in Fig. 1, but in the newer cards
they are made of iron. Iron flats are usually made If inches
wide with a strip of clothing \\ inch wide, and it is possible
to have 40 of them extending over an arc equal to about two-
fifths of the circumference of the cylinder. When wooden flats
19
COTTON CARDS
are used it is not possible to have so many. The functions
of these flats are the same as of those in the revolving flat
card previously described. The flats rest on the arch of the
card and are so constructed as to preserve the proper angle
with the card wire on the cylinder. Each flat is set inde-
pendently of any other by means of threaded pins secured
by nuts.
The peculiarity of this card consists in the method of
stripping the fiats. An arrangement is shown above the
machine in Fig. 1 by which any one flat may be raised from
its seat suflficiently to allow a stripping card to be passed
beneath it and drawn across its face, removing the impurities,
which are retained in a wire framework; immediately after
the stripping is completed the mechanism lowers the flat to
its position. As this one piece of stripping mechanism has
to clean each flat, it is necessary to have it so constructed
that it may be moved from one flat to another; this is
4 COTTON CARDS §19
provided for, as shown in Fig-. 1, by means of a small gear,
which is a part of the stripping mechanism, meshing with
a semicircular rack arranged on the arch of one side of
the card; as this gear revolves the mechanism is moved
from flat to flat. This can be arranged either to strip
the flats consecutively, thus the first, second, third, fourth,
and so on, or to strip them alternately, thus stripping the first,
third, fifth, seventh and returning to strip the second, fourth,
sixth, eighth, etc.; or in the improved quick stripper it may
be made variable in its action, in order to strip the flats
nearest to the feed-rolls oftener than those nearest to the
doffer. This stripper lifts, strips, and replaces a flat in less
than 4 seconds. The stationary-top flat cards are usually
made with all parts smaller than either the revolving-top flat
cards or the roller-and-clearer cards. The main cylinder is
not usually more than 42 inches in diameter and the dofEer
not more than 18 inches, while the width of the card is not
generally more than 37 inches. The construction of the
stationary-top flat card made it especially suitable to be used
in sections of a number of cards that delivered the slivers to a
traveling lattice. The latter conveyed them to a railway
head, a machine that combines all the slivers into one sliver
which it deposits into a can in suitable form for the next
process. This method was, and is still to some extent, used
where double carding is resorted to; however, owing- to the
comparatively small amount of the production for the floor
space occupied and the difflculty of arriving at accurate set-
tings and adjustment, especially where wooden flats are used,
it is now largely replaced by the revolving-top flat card.
A modern construction of a stationary-top flat card occupies
9 feet 6 inches by 5 feet 6 inches with a coiler, and 8 feet
2 inches by 5 feet 2 inches without a coiler. When making
a 60-grain sliver with the doffer making 10 revolutions it
cards about 60 pounds per day; it of course produces more
than this on coarse work with a heavier sliver and the doffer
running more quickly, and less for fine work with a slower
doffer speed and lighter sliver.
§19 COTTON CARDS
ROLL.ER-AND-CLEARER CARD
3. The I'oller-and-clearer card, a section of which is
shown in Fig. 2, although rarely used in America, is employed
to some extent in certain parts of Europe. The machine
consists primarily of a cylinder d, 45 inches in diameter,
which is covered with fillet card clothing and rotates at a
surface velocity of about 1,600 feet per minute. Placed over
this cylinder are a number of rollers e about 6 inches in
diameter, sometimes known as workers, and also a num-
ber of clearers / about 3i inches in diameter, some-
times called stri Pliers. Both the workers and clearers are
covered with fillet card clothing, the former rotating at a
surface velocity of about 20 feet per minute and the latter at
a circumferential speed of about 400 feet per minute. The
clearers are set in close proximity to the cylinder, and the
workers are adjusted both to the cylinder and to the clearers.
These settings are obtained by means of screws and setting
nuts with which the poppet heads g that support the shafts of
the workers and clearers can be adjusted. The clearers are
driven from a pulley d^ on the cylinder shaft by means of a
belt, or band, d., passing over pulleys on the clearer shafts
and also around a binder pulley //. The workers are usually
driven by a pulley on the doffer shaft that drives a belt, band,
or in some cases a chain passing around pulleys or sprockets
on the shafts of all the workers. The card is equipped with
an S-inch licker r, which is covered with fillet and rotates at
a surface velocity of about 700 feet per minute; a doffer j of
the ordinary construction is also employed.
In operation, a lap «, is placed in stands at the back of the
card and, resting on a rotating wooden roll a, is fed to the
card by means of a fluted feed-roll l\ and a feed-plate b. As
the licker c rotates downwards past the feed-plate, its
teeth take the cotton that is fed to it and carry it to the
cylinder d. The points of the teeth on the cylinder moving
rapidly past the backs of the teeth on the licker results in
the former taking the cotton from the latter and conveying
it to the doffer. In its passage from the licker to the doffer,
§19 COTTON CARDS 7
however, the cotton is subjected to the action of each of the
workers. The stock is held loosely and projects somewhat
from the teeth of the cylinder, which rapidly pass the workers
and operate point against point with the teeth of the latter.
The result of this is that the cotton is carded and opened out
and deposited on the workers, where it remains until the
rotation of the worker brings it under the action of the
clearer. Since the teeth of the clearer work with their points
against the backs of the teeth on the worker, they take the
cotton from the latter and convey it back to the main cylin-
der, which by virtue of its speed and the direction of inclina-
tion of its teeth, strips the cotton from the clearer. The
expressions point against point and point against back, when
referring to the card teeth of the various rolls, should not be
construed to mean that the teeth of any two rolls are in
actual contact, as these expressions refer only to the rela-
tive inclination of the card teeth. It will be noticed that the
first eight workers are arranged in pairs, each pair being
stripped by a single clearer, but that the last two workers are
each stripped by a separate clearer. Sometimes the entire
complement of workers and clearers are arranged as are the
last two in the illustration. The cotton is taken from the
cylinder by the doffer j in the ordinary manner and passed
to the coiler m through the trumpet k and calender rolls /, /,.
This form of card is apt to make a considerable amount of
flyings on account of the speed of the various parts, and in
order to prevent these from flying from the card the latter is
enclosed with a wooden cover n.
This method of carding results in the stock being thor-
oughly opened and cleaned, and it is claimed that it does
less damage to the fibers and that a yarn 5 per cent, stronger
can be produced than by the methods in more common use
at the present time. As this card, however, requires more
help to operate it and does not produce as much work as the
more recent card, its use is not considered profitable.
COTTON CARDS §19
DOUBLE CARDING
4. Formerly in order to obtain a high-grade yarn it was
considered necessary to adopt the principle of double card-
ing; viz., that of carding cotton first on a breaker card and
then, after having taken a number of the slivers and by means
of a lap head formed them into a lap, putting this lap through
a finisher card. Since the revolving flat card has been
improved so greatly that it does almost as good work as was
done with the old system of double carding, and since the
introduction of the comber, which produces work superior to
either double carding or revolving flat card products, double
carding is going out of practice.
5. Forniatioii of the Lap. — The cards employed in
double carding are similar to those already described and
need no further mention. The formation of the lap for the
second process of carding may be accomplished in several
ways: (1) Where the breaker cards deposit slivers in cans,
the lap is usually formed by means of a Derby doubler.
(2) Where the first carding is arranged in sections of six,
eight, ten, or twelve cards connected by a railway trough,
the slivers may be passed through a railway head, in which
they are deposited in a can, and afterwards passed through a
lap head. (3) The slivers from the section of a railway
trough may be guided directly into a lap head and the lap
formed in this manner.
The first method, that of using a Derby doubler, is an
arrangement by which a number of cans from the breaker
cards, varying from twenty to sixty, are placed behind a
long Y-shaped table and the sHvers from them passed through
rolls, forming at the front one wide sheet, which may be any
width from 10 to 40 inches. The lap is wound on a roll in
somewhat the same manner as a lap is formed in the picker
room. This lap is then placed on the lap roll at the finisher
card and recarded.
When it is desired to form a lap for the finisher cards
without the intervention of the railway head or can system
§19
COTTON CARDS
9
for each card, the slivers from the railway trough are guided
around rolls at such an angle as to arrange for slivers from
two or more lines of breaker cards to be guided into a lap
head and there wound into a lap usually half the width
necessary to supply the finisher card.
CARD CLOTHING
CONSTRUCTION
FOUNDATION
6. Card clothing: is the material with which the cylin-
der, doflfer, and flats of the card are covered and by means of
which the cotton is opened and the fibers straightened and
laid parallel to each other.
It consists of wire teeth
bent in the form of a staple
and inserted in a suitable
foundation material. The
teeth in addition to being
bent in the form of a staple,
also have a forward bend,
or inclination, from a point
known as the knee of the
tooth. Fig. 3 is an en-
larged view showing the
shape of a single card tooth
and the method of inserting it in the foundation y. The
knee of the tooth is shown aty^, while y^ indicates the portion
of the tooth, known as the crown, that is on the back of the
foundation after the tooth has been inserted in it; y, are the
points of the tooth, each tooth of course having two points.
7. Although the teeth of the clothing do the actual card-
ing, much depends on the character of the foundation, since
if the former are not held with considerable firmness and yet
allovv^ed a certain freedom of motion, the best results in carding
Fig. 3
10 COTTON CARDS §19
cannot be obtained. The foundation material must also be
such that it will not stretch after it is applied to the card,
for if the clothing becomes loose it will rise in places, or as
is commonly said, will blister. When this happens not only is
the thoroughness of the carding deteriorated, but there is also
great liability of the clothing itself being damaged by coming
in contact with the clothing on other parts of the card. In
addition, if the clothing is slack, the teeth will not be held up
to their work properly but will be forced backwards by the
strain in carding the cotton; this will result in neutralizing
to a certain extent the effect of the forward bend of the
tooth, making the clothing act more like a brush and allow-
ing the cotton to pass without being properly carded.
The foundation material generally used is a fabric woven
from cotton and woolen yarns, although sometimes cotton
and linen are employed, the linen being used on account of
its strength and freedom from stretching. The woolen yarn,
however, is well adapted for this purpose, as it possesses a
certain elasticity that, while holding the tooth in place with
sufficient security, allows a certain freedom of movement;
this is very desirable, since if the card teeth are held too
rigidly, there is some liability of their becoming bent or
broken. The foundation is generally woven three- or four-
ply, in order to obtain the required strength and the thick-
ness that is necessary to secure the teeth. A very good
foundation consists of a two-ply woolen fabric inserted
between two cotton fabrics, the latter imparting the requisite
strength and the former giving a firm but elastic grip on the
teeth. Sometimes the surface of the foundation is coated
with a veneer of india-rubber, but in this there are disad-
vantages as well as advantages. The rubber has a yielding
grip on the tooth that allows it enough freedom to move
when the strain of carding is on it, and at the same time it is
of a tough nature so that the movement of the tooth does
not work a large hole in the foundation, which would render
the teeth loosely secured so that the full benefit of the
elasticity of the wire could not be obtained. The india-
rubber-covered clothing is also much easier to strip, but on
§19 COTTON CARDS 11
the other hand is not so durable as clothing made with the
ordinary foundation. The rubber deteriorates with age,
becoming hard and stiff and cracking between the points
where the teeth pass through it. This deterioration is much
more rapid if the clothing is in a hot room or subjected to
the direct rays of the sun, and many times it has been found
that the foundation of rubber clothing was totally spoiled
before the wire was appreciably worn.
TEETH
8. The wire teeth actually do the carding, separating
the cotton, fiber from fiber, and rearranging it in a homo-
geneous mass in which the fibers lie more or less parallel;
they are therefore of even more importance than the founda-
tion in which they are inserted. The material from which
the wire is made, the number (diameter) of the wire, the
angle at which the wire passes through the foundation,
the angle at the knee of the tooth, the relative height of the
knee and point, and the method of insertion in the founda-
tion are all important considerations when card clothing
is to be purchased for general or special uses.
Clothing is set with many different kinds of wire, such as
iron, brass, mild steel, tempered steel, tinned steel, etc., but
for cotton carding hardened and tempered steel, which
makes a springy, elastic tooth that will not easily be bent
out of place or broken, is the best material. Mild-steel wire
wears too easily, losing its point and requiring frequent
grinding to keep the card in good working condition. On
the other hand it is easily ground, while tempered steel,
although necessitating less frequent grinding, is harder to
grind and requires a longer time to secure the required point,
since if the grinding operation is forced the wire is liable to
become heated and the temper drawn. The strength, elas-
ticity, and durability of the tempered steel, however, make
it much more desirable than any other material.
The wire generally employed is round in section, but
various other shapes have been used at different times; one
12 COTTON CARDS §19
of these was the elliptical form obtained by slightly flatten-
ing the round wire by passing it through heavy rolls. While
this form gave great strength to the tooth, it was objection-
able because the teeth had a tendency to work holes in the
foundation. After round wire has been set in the foundation
it is ground to a point, and this alters the form of the
section of the tooth at the point, or in some cases as far
down as the knee, although the part of the tooth that passes
through the foundation is always round in section. There
are three methods of grinding the clothing, which give to it
the following names: (1) top-ground; (2) 7ieedle-, or side-,
ground; (3) plozv-ground.
9. Top-ground wire is obtained by an emery grinding
roll having a very slight traverse motion, so that the point
of the tooth is ground down only on the top, producing what
is known as a flat, or eliisel, point.
In the needle-, or side-, ground \vire the thickness of
the tooth is reduced at the sides for a short distance from the
point, and the wire is also ground down at the top. This
form of point is known as the needle point and is produced
by a comparatively narrow emery grinding wheel that, in
addition to having a rotary motion, is rapidly traversed back
and forth across the clothing.
Both top and needle grinding are practiced in the mill, the
former being accomplished with the so-called dead-roll and the
latter with the traverse grinding roll, but plow grinding
is usually done by the manufacturers of the clothing. With
this method of grinding, the thickness of the wire is
reduced by grinding down each side from the point of the
tooth to the knee. This is accomplished by means of emery
disks that project into the clothing to the knee of the
tooth. To aid in this method of grinding, the teeth are
separated by means of plows, or guides, so that the emery
disk will pass between the wires and not knock down the
teeth, hence the name plow-ground. A plow-ground tooth
is the best, since it is not only strong, elastic, and easily
kept in good condition, but also gives a wedge-shaped space
§19
COTTON CARDS
13
between the teeth, which can more readily engage with the
cotton, and at the same time does not reduce the number of
points per square foot. It should be understood that plow
grinding alone does not give the necessary keen point to the
tooth, as it simply reduces the section of the tooth from the
knee up by grinding the sides fiat; consequently, after
the wire has been plow-ground it must be either top-ground
or needle-ground, in order to bevel the tooth and bring
it to a point.
10. Diameter of Wire. — The diameter of the wire
varies according to the class of cotton to be carded, since
fine cotton requires clothing with a large number of points
per square foot, while coarse work requires fewer points; and
in the former case fine wire must be used, while in the latter
case wire of a large diameter is more suitable. As will be
explained later, it is customary to set the clothing with a
certain number of points per square foot for a certain diam-
eter of wire. There are two gauges employed for number-
ing wire; namely, the Birmingham, or Stubbs, which is the
English standard, and the Brown & Sharpe, which is the
American standard. The following table shows the com-
parative diameters, expressed in decimal parts of an inch,
of. different numbers of wire of each system:
TABLE I
Birmingham
Diameter in Inches
Number of Wire
American
Diameter in Inches
.014
28
.012641
.013
29
•01 1257
.012
30
.010025
,010
31
.008928
.009
32 ■
.007950
.008
33
.007080
.007
34
.006305
.005
35
.005615
.004
36
.005000
14
COTTON CARDS
§19
For an average grade of cotton, No. 33 wire (American
gauge) for the doffer and flats and No. 32 for the cylinder
will give good results; for coarse work the wire is propor-
tionally increased in diameter, and for finer work proportion-
ally decreased. The cylinder should always be covered with
wire one number coarser than the doffer and fiats, which
should have wire of the same diameter.
11. In regard to the shape of the tooth and the angle at
which it is inserted in the foundation, several important points
should be noted. The knee of the tooth should be located
about four-sevenths of the length of the tooth from the crown
and three-sevenths from the point. If the knee is placed
higher the tooth will be stronger and have a harsher action
on the cotton, while if the knee is lower the clothing will be
more flexible and have a more brush-like action. The tooth
should penetrate the foundation at an angle of about 75°, to
offset the bend at the knee, so that the point of the tooth will
not be too far forwards.
The angle of insertion in
the foundation and the
bend of the knee should
be such that the point of
the tooth will just touch or
very slightly pass a per-
pendicular line drawn
from the point where the
tooth emerges from the foundation. Should the' forward
inclination be such that the tooth passes the perpendicular to
any great extent, the point of the tooth will rise when it is
moved back by the strain of carding. This is more clearly
shown by reference to Fig. 4. Suppose that the shape of the
tooth is such that its point is inclined forwards past the per-
pendicular y^, I's, as shown at .r^; then when the strain comes
on the tooth, the point will be moved back to ye, owing to the
flexibility of the tooth and the freedom of motion allowed by
the foundation. The point, therefore, in swinging through the
arc ^3^6 will rise through the distance x, which in the case of
Fig. 4
§19
COTTON CARDS
15
a close setting might be sufficient to make the wire strike the
clothing on other parts of the card. This action of the tooth
is also aggravated by the tendency to straighten at the knee,
so that even if no contact results, the setting will be made
much closer and many fibers will be broken. On the other
hand, if the inclination of the tooth does not carry its point
past the perpendicular, the tendency of the tooth in moving
backwards under the strain of carding will be to depress the
point, making the setting more open and reducing the strain.
Four Crowns Per Inch
Fig. 5
CALCULATIONS
12. Card clothing for cotton cards is made in long con-
tinuous strips 1, li. li, II, and 2 inches in width known as
fillet, or filleting, and in narrow sheets known as tops; the
former is used for covering the cylinder and doffer, while the
latter is used for the flats. Fillet clothing is made in what is
known as rib set; that is, with the crowns of the teeth.
16 COTTON CARDS §19
which are on the back of the clothing, running in ribs, or rows,
lengthwise of the fillet. Fig. 5 shows the appearance of the
back of a piece of li-inch rib-set fillet, the horizontal lines
indicating the crowns of the teeth and showing the method
in which they are inserted. The teeth are set into tops so
that the crowns of the teeth on the back side of the founda-
tion are twilled; that is, they are set in diagonal lines like
a piece of twilled cloth. Fig. 6 shows the appearance of the
back of a top, the horizontal lines showing the method of
twilling the crowns.
Four Crowns Per Inr.''
Fig. 6
All card clothing in America, unless especially ordered, is
made with 4 crowns in 1 inch on the back of the clothing, or
8 points in 1 inch on the face, and is known as 8-crown cloth-
ing. From this it will be seen that a 2-inch fillet will have
8 ribs on the back and a li-inch fillet, 6 ribs, etc. It should
be noted that the actual width of the foundation of fillet
clothing is about -?w inch greater than the width of the wire-
covered space; thus, a 2-inch fillet is actually 2tV inches in
width. Sometimes in special cases where a large number
of points per square foot are desired, the clothing is made
§19 COTTON CARDS 17
10-crown; that is, with 10 points per inch in width on the
face of the clothing, or 5 crowns per inch on the back of
the clothing.
The term iiogg, which is used in connection with card
clothing, refers to the distance between the first tooth of one
line of twill and the next line. It will be noticed in Fig. 6
that there are 6 teeth to a nogg and 8 noggs per inch, while
in Fig. 5 there are half as many teeth per nogg and 16 noggs
per inch. Owing to the manner in which the teeth are set in
fillet clothing, there are always one-half the number of teeth
per nogg and twice the number of noggs per inch as in cloth-
ing for tops with the same number of points per square foot.
The number of noggs per inch always governs the number
of points per square foot in the clothing. If more points per
square foot are wanted, the noggs per inch are increased,
while if fewer points are wanted, the noggs per inch are
decreased, the crowns always remaining the same.
13. To find the points per square foot in card clothing:
Rule. — Muliiply the crowns per hich by the points per tooth
(2), by the teeth per nogg, by the noggs per inch, aiid by the
number of square inches in a square foot (144).
Example 1. — Find the points per square foot in the sample of card
clothing shown in Fig. 5, the crowns per inch being 4, the teeth per
nogg 3, and the noggs per inch 16.
Solution.— 4 crowns per in.
2 points per tooth
8 points per in.
3 teeth per nogg
24
1 6 noggs per in.
24
3 8 4 points per sq. in.
1 4 4 in. per sq. ft.
153 6
1536
3^4
5 5 2 9 6 points per sq. ft. Ans.
18 COTTON CARDS §19
Dividing the points per square foot by the noggs per inch,
thus, 55,296 -=- 16 = 3,456, it will be noticed that with 8-crown
fillet (4 crowns per inch) each nogg increases the points per
square foot by 3,456. From this it will be seen that in order
to find the points per square foot in 8-crown fillet clothing,
it is only necessary to multiply the noggs per inch by 3,456.
Example 2. — Find the points per square foot in the sample of card
clothing shown in Fig. 6, the crowns per inch being 4, teeth per
nogg 6, noggs per inch 8.
J Solution. — 4 crowns per in.
2 points per tooth
8 points per in.
6 teeth per nogg
4 8
8 noggs per in.
3 8 4 points per sq. in.
144
153 6
1536
384
5 5 2 9 6 points per sq. ft. Ans.
Dividing the points per square foot by the noggs per inch,
thus, 55,296 ^ 8 = 6,912, it will be noticed that with 8-crown
twill-set clothing each nogg increases the points per square
foot by 6,912. From this it will be seen that in order to
find the points per square foot in twill-set clothing it is only
necessary to multiply the noggs per inch by 6,912.
In Table II is given the number of points per square
foot of 8-crown, rib-set fillet (4 crowns per inch) with 3 teeth
per nogg and with from 10 to 27 noggs per inch, and also
shows the numbers of wire (American gauge) generally used
in each case.
In Table III is given the number of points per square
foot of 8-crown, twill-set clothing with 6 teeth per nogg and
with from 5 to 13 noggs per inch and also shows the numbers
of wire (American gauge) generally used in each case.
For an average grade of cotton the doffer should have
20 or 21 noggs per inch and the flats 10 or lOl^ noggs per
19
COTTON CARDS
TABLE II
19
Noggs per Inch
Points per Square
Foot
American Number
of Wire
10
34,560
28
1 1
38,016
28
12
41,472
29
13
44,928
29
M
48,384
30
15
51,840
30
i6
55,296
31
17
58,752
31
i8
62,208
32
19
65,664
32
20
69,120
33
21
72,576
33
22
76,032
34
23
79,488
34
24
82,944
35
25
26
86,400
89,856
35
36
27
93,312
36
TABLE III
^
Noggs per Inch
Points per Square
Foot
American Number
of Wire
5
34,560
28
6
41,472
29
7
48,384
30
8
55,296
31
9
62,208
32
lO
n
12
69,120
76,032
82,944
33
34
35
13
89,856
36
20
COTTON CARDS
§19
inch, which in each case would give 69,120 or 72,576 points
per square foot. For the main cyUnder 18 or 19 noggs per
inch are suitable, which would give 62,208 or 65,664 points
per square foot. The number of points may of course be
varied to suit the class of work, but it is generally desirable
to have the same number of points in the dolifer and flats,
Fig. 7
while the main cylinder should have a slightly smaller num-
ber than either.
14. English Method of Nmiibering Card Clothing:.
English card clothing was formerly made with the teeth
inserted according to a method known as the plain-, or
open-, set, in which the crowns, or backs, of the teeth over-
lapped each other exactly as bricks in a wall, as shown in
Fig. 7. The teeth were inserted in sheets 4 inches in width,
§19 COTTON CARDS 21
and the clothing- was made with 5 crowns on the back, or
10 points on the face, in 1 inch lengthwise of the sheet, or
crosswise of the card after the sheet had been applied to the
same; that is, it was 10-crown clothing. Plain-set clothing
is not often used in America, and although rarely used in
England today, it forms the basis of the whole English
system of numbering clothing. The English system desig-
nates card clothing by the counts, a term that indicates
the number of points per square foot on the face of the
clothing absolutely, but which gives no clue to the method
of inserting the teeth, whether plain-, rib-, or twill-set; that is,
lOOs-count card clothing indicates a definite number of points
per square foot and nothing else.
As stated, the English system of numbering card clothing
is based on the 10-crown, plain-set clothing, the term counts
indicating the number of noggs in 4 inches, which was the
original width of the sheets. Thus, if a sheet of plain-set,
10-crown clothing had 60 noggs in its width, it was 60s-count,
or if it had 100 noggs in the width of the sheet, it was
lOOs-count clothing, etc. As plain-set clothing was invari-
ably made on the 10-crown basis, the number of noggs
in the width of the sheet, or the counts, always indicated a
definite number of points per square foot. For example, in
lOOs-count clothing, as there are 100 noggs in 4 inches, then
in 12 inches, or 1 foot, there are 300 noggs, and as in
plain-set clothing there are 2 teeth per nogg, there are
300 X 2 = 600 points crosswise of the sheets. Since
10-crown clothing has 10 points per inch, there are
10 X 12 = 120 points in 1 foot lengthwise of the sheet,
which multiplied by 600 points per foot crosswise of the
sheet equals 72,000 points per square foot. From this it
will be seen that as lOOs-count clothing contains 72,000
points per square foot, each count increases the points per
square foot 72,000 -^ 100 = 720 points. Therefore, to find
the points per square foot in card clothing of any counts, it is
only necessary to multiply the counts by 720; and inversely,
to find the counts of any card clothing, divide the points
per square foot by 720.
22
COTTON CARDS
§19
Although plain-set, 10-crown clothing has been largely-
superseded in both England and America by 8-crown, twilled-
set clothing for the flats and 8-crown, rib-set clothing for the
cylinder and doffer, the English system of numbering cloth-
ing is still based on the plain-set clothing, in which each
count is equal to 720 points per square foot. Table IV
shows the points per square foot in card clothing of various
counts and also the number of wire (American gauge) that
is usually used.
TABLE IV
English Counts
Points per Square
Foot
American Number
of Wire
60s
43,200
28
70s
50,400
30
80s
57,600
31
90s
64,800
32
IOCS
72,000
33
lies
79,200
34
I20S
86,400
35
130s
93,600
36
METHOD OF CEOTHING CARDS
CLOTHING FLATS
15. The clothing for the flats is made in sheets with a
1-inch space between the sections of wire; these are after-
wards cut up to form the tops. Formerly one of the most
difRcult probleins for cotton-card builders and manufacturers
of card clothing was to attach satisfactorily the top to the
flat. The first method employed was to drill holes in each
edge of the flat and secure the clothing by rivets. This
method, while it held the clothing securely, had a tendency
to weaken the flats, causing them to deflect; and in addition,
the cotton occasionally caught on the rivets until a bunch
was formed, which would pass into the card again and form
§19 COTTON CARDS 23
a nep in the web. Another method was to sew the top to
the flat, but this was not entirely satisfactory.
The present method is to employ a steel clamp of the
same length as the clothing and bent in a U-shape. One
edge of this clamp in some cases is serrated, so as to grip
the foundation, while the other edge engages the edge of
the flat, holding the clothing and flat securely together. The
foundation of the card clothing is pulled toward the edges of
the flat and clamps applied simultaneously to both edges,
so that the clothing is fastened while under tension. After-
wards end pieces are usually fastened on in order to make
the clothing absolutely secure. The flats should be ground
after the clothing is applied, so as to make them perfectly true.
CLOTHING CYLINDER AND DOFFER
16. Both the cylinder and doffer, which are covered with
filleting, have parallel rows of holes drilled across them,
which are plugged with hardwood. The fillet is wound
spirally and secured by means of tacks driven in the hard-
wood plugs. Cylinders are usually covered with 2-inch, and
doffers with li-inch, filleting. Formerly it was customary to
give the surface of the cylinder a thin coat of paint or cover
it with calico before applying the clothing, buf the present
practice is to wind the fillet on the bare cylinder. The plugs
should be flush with the surface of the cylinder, which should
be smooth, free from rust, and perfectly dry before the cloth-
ing is applied. Since the fillet is wound spirally, it must be
tapered at each end of the cylinder or doflfer, so that it will
not overlap.
17. There are several methods of shaping the tail-ends,
as they are called, but the best is that known as the inside
taper, since it is stronger and neater than any other.
Fig. 8 (rt) shows the method of cutting the fillet for an
inside taper. Three lengths ;*:, ;c,, x., each equal to one-half
the circumference of the cylinder or dofTer, as the case may
be, are first miarked out on the end of the fillet; in the case
of a 50-inch cylinder these distances x, x,, x^ would be
24
COTTON CARDS
§19
'j~m'\
§19 COTTON CARDS 25
6.545 feet each. For the first distance x, the fillet is cut
exactly through the middle; for the second distance ,v,, it
is tapered from half the width of the fillet to the full width;
for the distance .v,, a cut is made on the opposite side of the
fillet exactly half way through it and the fillet tapered out to
its full width again. The dotted lines in Fig. 8 (a) indicate
the original width and shape of the fillet, while the full lines
show the shape of the tail-end when cut. Fig. 8 (d) shows
the method of winding the fillet on the cylinder and the way
the tail-ends are fastened. After one tail-end is cut, the end
of the fillet is tacked to the plugs in the cylinder and the fillet
wound around the cylinder spirally, as shown in Fig. 8 (b)
and (c); the other tail-end is then cut and fastened to the
cylinder in the same manner as the first tail-end. Care
should be taken in cutting each tail-end to have the straight,
or uncut, edge of the fillet x, x, coincide with the edge of the
cylinder. Fig. 8 {c) shows the opposite side of the cylinder
shown in Fig. 8 (<^).
18. To find the length of filleting to cover a cylinder,
doffer, or other roll:
Rule. — Mtdtiply the diameter of the roll by its width {both
expressed i?i inches) ayid by 3.1416 and divide the product thus
obtained by the width of the fillet midtiplied by 12. The result
thtis obtaijied will be the required munber of feet of filleting.
Note. — An allowance must be made for tapering the tail-ends, g:en-
erally a length equal to the circumference of the roll being sufficient.
ExAMPLK. — What length of 2-inch filleting is required to clothe a
cylinder 50 inches in diameter and 40 inches wide?
„ 50 X 40 X 3.1416 _, ^ ^^
Solution. — ^^ = 261.8 ft.
Adding a length equal to the circumference of the cylinder, which
is 13.09 ft., the length required will be 274.89 ft. Ans.
19. Filler-Winding Macliine. — Before applying the
fillet, it should remain for several days in the room in which
it is to be used; otherwise, it will have a tendency to expand
after being fixed on the cylinder, which causes it to rise in
26
COTTON CARDS
19
places. The fillet is applied to cylinders or doffers by means
of special winding machines; formerly it was wound by hand.
Fig. 9 shows a good type of fillet-winding machine, which
consists primarily of a carriage a that slides on a bed b.
Sufficient motion is imparted to the carriage, by means of a
rotating screw c that engages with a gear r, on a shaft, to
guide the spirals of fillet close to each other. The gear r,
is prevented from turning, after the position of the machine
Fig. 9
is once adjusted with the crank c^, by a lever r,, which
operates a screw that secures its shaft. The fillet when being
wound is usually placed in a basket, or other receptacle, from
which the end is taken and passed through the trough d to
what is known as the cone drum e, around which it is wrapped
three times. The fillet emerges over the roll / and is guided
on the cjilinder to be clothed by the rod g. The fillet must
always be passed through the trough d so that the teeth will
§19 COTTON CARDS 27
point in the opposite direction to its motion; otherwise, they
will be injured.
The tension is obtained in the following manner: The
drum e, which revolves as the fillet passes over it, is made
in three sections — the first 6^ inches, the second 7 inches,
and the third 1\ inches in diameter. The section with the
largest diameter is covered with leather, so that this portion
of the drum and the fillet revolve together; and as it requires
a greater length of fillet to cover this surface than it does to
cover either of the smaller sections, the fillet is drawn over
these at a speed greater than that of their surfaces, which
will have the same effect as if the smaller sections were
working in a direction opposite to that of the larger section.
The friction between the fillet and the drum produces the
tension on the former, the amount of which may be regulated
by the brake // on the drum shaft and also by a thumbscrew/
that presses the die k down on the fillet, which is drawn over
a spring cushion in the trough d. About 200 pounds ten-
sion may be obtained by means of the brake h alone, the
rest being obtained by means of the thumbscrew j. For
main cylinders wound with 2-inch fillet, a tension of 270 to
300 pounds is about right; narrower fillet requires less ten-
sion. Dofifers may have fillet applied with about 175 pounds
tension. The amount of tension with which the fillet is being
wound in this machine is indicated by a finger / on the dial f^.
This is accomplished by arranging the roll / to press against
a strong coil spring Z^, connection being made with a rack A
and pinion A, so that the motion of the roll when acted on
by the tension of the fillet is communicated to the finger and
indicated on the dial.
In using this machine, it is essential that for each revolu-
tion of the cylinder being covered the carriage shall move
along the bed a distance corresponding to the width of the
fillet. This is accomplished by gearing the screw that
imparts the traverse motion to the carriage from the cyl-
inder being covered, the train of gears being so arranged
that one tooth of the change gear moves the carriage isV inch
to each revolution of the cylinder being covered. From this
28 COTTON CARDS §19
it will be seen that 1^-inch fillet will require a 48-tooth gear
and 2-inch fillet a 64-tooth gear. In actual practice, however,
a 49-tooth gear is used for H-inch and a 66-tooth gear for
2-inch fillet, since the fillet is wider than the nominal width
and measures I32 inches and 2tV inches, respectively. A
crank arrangement is usually applied to the cylinder and
dofiEer so that they can be turned by hand while the clothing
is being applied.
After cylinders are covered with fillet they should be
allowed to stand for 8 or 4 hours in order that the fillet may
become adjusted, when it should be tacked crosswise of the
cylinder.
COTTON CARDS
(PART 3)
CARE OF CARDS
INTRODUCTION
1. The method of managing a card room very materially
affects the quality of the product of a cotton mill, as in order
to insure satisfactory results it is very essential that the card-
ing process shall have careful attention. Care should espe-
cially be given to several important operations that must be
performed at intervals.
Those parts of the card that are clothed — the flats, the
cylinder, and the doffer — are constantly collecting waste from
the cotton that is being operated on. This waste, consisting
of short fiber and foreign matter that fills up the interstices
of the card wire and prevents the card from doing its best
work, must be removed at intervals from the clothing, the
process being known z.s stripphig. Fig. 1 is a view of a card
showing arrangements applied for stripping the doffer and
fiats.
As the points of the card wire become dull, on account of
the constant friction, and consequently do not card the cotton
as satisfactorily as when sharp, they must be sharpened by
means of emery rolls; this is accomplished by the process
known as grinding. A view of a card, w'ith arrangements
applied for grinding the doffer and cylinder, is shown in
Fig. 2.
When two wire surfaces are presented to each other, there
For notice of copyright, see page immediately following the title page
30
COTTON CARDS
§19
19
COTTON CARDS
31
32 COTTON CARDS §19
is sometimes too much space between them, caused by parts
of the card moving slightly out of position or by the shorten-
ing of the wire by the grinding process. The operation of
regulating the distance between the two wire surfaces is
known as setting.
In common with all machinery, the oiling of the parts
must be periodically attended to, as well as the cleaning of
the machine and the removal of fly from below^ the card.
Very little more attention is necessary in connection with
carding cotton with the revolving-top flat card other than
keeping the machine supplied with laps and removing the
cans when full.
STRIPPING
2. Methods of Stripping. — Various methods of strip-
ping cards have been adopted. One of the earliest methods
used in cotton carding, and one that is now in use in connec-
tion with w^oolen carding, was by means of a flat board from
4 to 6 inches wide and as long as half the width of the card,
on the upper part of which a handle was attached, while a
piece of card clothing was nailed on the lower part with the
safe'
Fig. 3
points projecting toward the operator. The cylinder was
slowly turned by hand, after it had been partly uncovered
at the front, and the stripping card pressed into the wire of
the cylinder and alternately pushed backwards and drawn
forwards, the latter movement removing the waste from the
cylinder. A similar operation cleaned the waste from
the doffer.
§19 COTTON CARDS 33
A much better method of stripping the card and the one
now commonly adopted is by means of a stripping roll, such
as is shown in Fig. 8. This roll consists of a wooden cylin-
der mounted on an iron shaft and having wire clothing wound
around it so as entirely to cover its surface, although on
some rolls a narrow space without teeth is left from one end
to the other. The clothing used for the stripping roll carries
a very much longer tooth than that used to cover the cylinder
or doflPer, and the wire teeth are not set so closely together.
3. Frequency of Strii^ping. — The number of times
that a card should be stripped within a stated period will be
found to vary, but it may be said to depend on two factors.
One is that the greater the weight of cotton that is put
through the card per day, the more frequently it should be
stripped; the other is that in fine work the clothing should
be kept as free as possible from short fiber and particles of
foreign matter, so that when running fine work the card should
receive more frequent stripping, notwithstanding the fact
that a lighter weight of cotton is being put through the card
than in coarse work. It may be stated as a common practice
that for fine work the card should be stripped three times a
day unless a very large production is being obtained, when
it is advisable to strip four or even five times per day, while
with a medium production and where a very high grade of
work is not called for, it is not necessary to strip the cylinder
and dof?er more than twice a day.
To stop a card for stripping purposes necessarily means a
reduction in the amount of product, but by carefully planning
so that the card will not be stopped any longer than neces-
sary before it is stripped, and by getting it in operation
again immediately after stripping, the loss can be reduced
to a very small amount. In stripping cards two men are
usually employed, since one cannot readily handle the long
stripping roll; and time can also be saved by having one
man preparing the next card for stripping while the other
man is performing the operation of restarting the card pre-
viously stripped and removing the strippings from the
34 COTTON CARDS §19
stripping roll. Since it is the usual practice to strip the
cylinder before stripping the dofifer, time may also be saved
by starting the feed while the dofiEer is being stripped. In
this manner the cylinder will be filled and the sliver will be
ready to be pieced up as soon as the stripping action is
completed. In order to economize in the amount of strip-
pings removed from the card, the feed-roll and calender
rolls should be stopped a short time before the card is
stopped, thus allowing the good cotton to run through the
card and drop on the floor in front of the doffer; it is then
removed and returned to the mixing room.
4. Operation of Stripping. — The operation of stripping
is as follows: The card is first stopped by shipping the
driving belt from the tight to the loose pulley. The feed-
roll should have been previously stopped by disengaging the
side shaft Wi,, Fig. 2, at the dofifer, and the gear ;;;,3, Fig. 1,
should also have previously been thrown out of gear by
means of the handle, thus stopping the calender rolls and
coiler and allowing the good cotton to run through the card
until exhausted, as previously stated. As the cylinder is the
first to be stripped, the cover, or door e^, that protects the
cylinder at the front and is hinged on the arms r,o, is lowered
so as to leave the cylinder bare at that point. The stripping
roll is now placed in the upper set of bearings 7\ and a band
run from the outer groove of the loose pulley of the card to
the grooved pulley on the end of the stripping roll. This
band should be crossed in order to give the correct direction
of motion to the stripping roll. With the stripping roll in
this position its teeth should project a slight distance into
the wire of the cylinder, usually about i inch, and should
point in the direction of revolution of the roll. At the
point where the roll is in contact with the cylinder, the teeth
of both are pointing in the same direction and the surface
speed of the roll is greater than that of the cylinder, thus
making the stripping possible. The driving belt of the
card is now moved suflficiently on to the tight pulley
to turn the cylinder slightly and at the same time leave
§19 COTTON CARDS 35
enough of the belt on the loose pulley to give the necessary
power to drive the stripping roll.
It is advisable for the operator to be able to control the
speed of the stripping roll at all times and to stop it sud-
denly if necessary. On this account the band that runs from
the loose pulley to the stripping roll is not usually tight, the
stripper creating sufficient tension to drive the stripping roll
by pressing his hand on the band. By this means the wire
teeth on the rapidly revolving stripping roll remove the
waste from the spaces between the teeth of the card wire
on the cylinder, thi's waste adhering to the surface of the
stripping roll. In performing this operation, care should be
taken that the cylinder does not attain a greater surface
speed than the roll, since in this case the excess surface
speed of the cylinder will cause the waste to be taken from
the roll by the cylinder.
After the cylinder has made one complete revolution, the
band that drives the stripping roll is removed and the strip-
ping roll taken from the stands j\ and cleaned and then placed
in lower stands at the doffer, as shown in Fig. 1. A band
somewhat longer than the one previously used is then run from
the loose pulley of the card to the grooved pulley on the
stripping roll r. This band is also crossed, and the operation
of stripping the doffer is performed in the same way as that
of stripping the cylinder. It is the practice in some mills,
especially those making coarse counts, to run the card
while stripping the doffer. This, however, is not good
practice, since the stripping roll throws out considerable
dirt, a good part of which is liable to drop into the web and
be carried through into the finished sliver.
5. Cleaning the Stripping Roll. — After stripping the
cylinder of each card, and also the doffer, the strippings
retained by the stripping roll should be removed from the
stripping roll. These strippings may be removed by a hand
card or by placing a finger in the narrow space that is
without wire teeth, when one is left in the stripping roll,
breaking the circular web at this point, and unrolling it from
86 COTTON CARDS §19
the roll. Another method of removing the strippings from
the stripping roll and one that is used in a large number of
mills is to employ a box that is placed on wheels. This box
is usiially about 18 inches wide, 3 feet deep, and long enough
to allow the clothed part of the stripping roll to rest between
its ends, while the ends of the shaft rest in V-shaped grooves
in the ends of the box. A strip of wood about 4 inches wide
covered with card sheets is fixed between the ends of the
box in such a position below the stripping roll that the wire
teeth of the roll will just enter the wire of the sheets when
the shaft of the roll is set in the grooves in the ends of the
box. When cleaning the roll, it is turned by hand with a
backward and forward movement, which causes the strip-
pings to be removed and dropped into the box. This method
is quicker and better than the hand card and provides a place
for keeping the roll. The box also serves as a receptacle for
the strippings.
It will be noticed that a card immediately after being
stripped produces a sliver slightly lighter in weight, w^hich
is due to the spaces between the teeth of the clothing filling
up again with fiber. In mills where it is desired to make
exceptionally even yarns it is not advisable to strip at one
time all the cards supplying one subsequent machine, but
to take them in sections of either two or four supplying
dififerent machines.
GRINDING
GRINDING ROLLS
6. Grinding is the process of sharpening the teeth of
the card wire on the cylinder, dofifer, or flats by means of
rolls called grindinjj: rolls, and is of great importance in
connection with carding. Formerly when mild-steel wire
was used grinding had to be performed frequently. The
clothing, however, that is almost universally used at the
present time is made of hardened-and-tempered-steel wire
that is ground on the sides after having been inserted
§19
COTTON CARDS
37
through the foundation; consequently, the tooth is almost
wedge-shaped, so that even when the extreme point is worn
away there still remains a comparatively sharp tooth. Grind-
ing is therefore required less frequently
than formerly, not only because the hard-
ened -and -tempered -wire retains its point
longer, but also on account of the shape
of the tooth.
7. Dead Kolls. — Grinding rolls are
of two kinds — the dead foil and the traverse
grinder. The dead roll is shown in Fig. 4.
It consists principally of a hollow shell s
mounted on a shaft s^. This shell is cov-
ered with emery fillet wound spirally on its
surface. At the ends of the shell, where
the fillet tapers to a point it is passed
through slots, one of which is shown at s-^,
• and is firmly fastened by means of a steel
■ clip setscrewed to the inner side of the
shell. A dead roll suitable for grinding
purposes on a 40-inch card is about 42
inches long and 6f inches in diameter.
When grinding, the dead roll is given a
slight traversing motion and grinds the
back of the teeth with a slight tendency
toward grinding the sides. The traversing
motion is obtained in the following manner:
The shaft that carries the shell s projects
beyond both ends of the shell sufificiently
to carry at one end the worm ^4 and at the
other end the pulley ^,, through which the
roll receives its rotary motion; this pulley
is driven by a band that passes around the
grooved pulley on the end of the cylinder
shaft of the card. The worm s^, which is fast to the shaft s,,
drives a worm-gear ^5 that carries a pin s^ set away from the
center of s^ and loosely connected to the rod s-,, the other end
^
38 COTTON CARDS . §19
of the rod being connected to the bracket ^e, which is loose on
the shaft s^. Connected to the bracket Ss by means of a short
rod is another bracket s^, that is loose on the shaft 5.. The
two brackets Ss, s^ enclose a brass bushing- 5,„ that rests in
one of the bearings for the grinding roll when the roll is in
position, while a similar bushing on the other end of the
shaft rests in the other bearing. Pins on these bushings
project into holes provided in the bearings and thus hold the
bushings firmly in one position. These bushings are loose
on the shaft s,; consequently, the shaft is free to revolve
and also to move laterally. With this construction, it will
be seen that as the worm s^ drives the worm-gear s^, the
latter, acting as an eccentric because of the position of
the pin s^, will tend to impart a reciprocating motion to
the brackets Ss,s^ through the connecting arm j-,, but will
be prevented from doing so on account of these brackets
being held in one position by means of the bushing Sio-
Since the brackets are stationary, the rod s, and the pin Se
that connects it with the gear s, can have no lateral move-
ment; consequently ^5, by its eccentric movement around Se,
will, through its bearing in the gear-cover, a portion of
which is shown broken away in Fig. 4, and through the
collars on the shaft at each side of the cover, impart a
traversing movement to the shaft s, and the roll .?. Dead
rolls are used for grinding the flats of the card, but seldom
for grinding the cylinder or doffer, it being the custom to
grind these two parts with the dead roll only when they
have been newly clothed or when their surfaces become
very uneven.
8. The Traverse Grinder. — The second type of
roll, known as the traverse grinder, or sometimes as
the Horsfall grinder, is shown in Fig. 5. It consists of a
roll t about 4 inches wide covered with emery fillet and
mounted so as to slide on a hollow barrel, or shell, of large
diameter. Inside the barrel is a shaft containing right- and
left-hand threads connected at the ends. A fork /, fits into
these threads, and a pin that projects from it passes into
40 COTTON CARDS §19
another pin /« that projects into a straight slot in the outer
barrel and enters the roll. There are two pulleys, one of
which /o is on the inner shaft, while the other t^ is on an
extended portion of the barrel. With this construction the
barrel is rotated when t^ is driven; the pressure of the edge
of the slot against the pin t^ when the barrel is revolved
causes the grinding roll also to revolve. A traverse motion
is also imparted to the roll / by driving the pulley /;,, which
causes the fork /, to be moved from side to side, changing
from one thread to the other at each side of the card. Since
the grinding roll presses against the clothing, the result of its
traverse motion is to cause the teeth that are in contact with
it to be bent, or inclined, toward the side of the card to which
the roll is moving. The result of this is that the sides of the
points of the teeth are ground down slightly, as well as the
top of the points. In consequence of the roll being so
narrow, it requires a longer time to grind the card with this
mechanism than with the dead roll, other conditions being
the same, but the results are so much better that it is very
largely used. There is an unavoidable dwell on each side,
which tends to grind down the sides rather more than the
center; this is the only other important disadvantage in the
use of this grinder.
Grinding rolls, whether traverse grinders or dead rolls, are
usually covered with emery fillet; this is a tape 1 inch wide
covered on one side with emery, and is supplied in lengths of
about 300 feet. It can be obtained with emery of different
degrees of coarseness or fineness, the kind generally used
for card grinding being known as No. 40.
PREPARATION FOR GRINDING
9. All grinding is usually performed by a man known as
a grinder, who in large mills has from twenty to sixty
revolving-top flat cards under his charge. The cards are
usually ground in turn, unless some accident or defect neces-
sitates some card to be ground out of the regular order.
Before the grinding takes place, however, the card must be
§19 COTTON CARDS 41
prepared for this purpose, and the operation is somewhat as
follows: The lap is either broken off at the back and the end
allowed to run through, or more usually the side shaft ;;/,2,
Fig. 2, is disengaged and the feed-roll turned backwards by
turning the plate bevel gear b^ in the opposite direction from
that in which it usually revolves. This rolls up the sheet
and takes the fringe of cotton away from the licker. Any
cotton in the card is allowed to run through and the cylinder
and doffer are then stripped clean of short fibers, care being
taken that no cotton remains on the part stripped. The
card is then started and the flats allowed to run bare of all
strippings; this takes from 25 to 40 minutes, according to the
speed of the flats and nature of the cotton being carded. The
card is then stopped and the fly taken out from under the
card and from between the sides of the cylinder and frame-
work and between the sides of the doffer and framework,
where it collects. Card makers have in late years greatly
lessened this space and in so doing partly reduced the amount
of fly at these points. This waste is sometimes called
cylincler-eiid >vaste, and is removed from these parts by
means of a long, thin hook usually made from a bale tie.
Fly also collects around the shaft that connects the sprocket
gears that drive the flats. Care should be taken to remove
all loose fly from around and under the card before grinding
is commenced. If any remains there is great danger of fire,
as sometimes the grinding roll strikes sparks.
After making certain that the gear ;«,3, Fig. 1, and the
side shaft, w,,. Fig. 2, which where thrown out of gear
before stripping, are well out of contact, disengage the
doffer and barrow gears by throwing up the front end of the
catch /«, Fig. 1, which will drop the lever L that supports
the barrow gear. The licker belt, flat belt, and comb bands
may then be removed. In some cases, when grinding, it is
necessary to remove the pulley on the shaft with the worm
that drives the flats, in order to accommodate the bands that
are placed on the card for grinding, but where this is not
necessary the flats should always be run with their driving
belt reversed, so that when the direction of rotation of the
42 COTTON CARDS §19
cylinder is changed for grinding, as described later, the flats
will move in the same direction and at the same speed as
when carding. If the flats are stationary during the grinding
process they will be filled with dirt by the cylinder, and the
first cotton that is put through the card after grinding will
have to be considered as waste on account of the unclean
condition of the flats.
During grinding, the cylinder is driven at the usual speed
but in the opposite direction to that in which it is driven for
carding purposes. It is necessary to reverse its direction in
order that the back of the tooth may be presented to the
grinding roll when grinding. If the front of the tooth were
presented to the grinding roll, the tooth would be beveled off
at the front, which is directly the reverse of what is desired;
in addition to this, the grinding roll acting on the front of the
tooth would tend to raise it from its foundation and cause
it to stand higher than it should. In order to reverse the
direction of the cylinder it is necessary to cross the driving
belt, if it was previously open; but if the belt for driving the
cylinder when carding was crossed, it is simply necessary to
have the belt open when grinding. If it is necessary to cross
the belt when grinding it will be somewhat tight; to avoid
this it is sometimes the custom to use an extra belt of the
right length, which is carried from card to card by the
grinder, although the same belt is more often used for both
grinding and carding. In this case, if the belt was crossed
when carding it must be taken up when used for grinding.
This is accomplished by punching two holes in a line cross-
wise of the belt and two holes similarly placed but a short
distance from the first holes and inserting a lacing of horse-
hide, thus forming a loop in the belt. The distance between
these two pairs of holes depends on the amount of slack that
it is necessary to take up in order to drive the cylinder with
an open belt.
The dofifer when being ground is driven in the same
direction as for carding purposes, but at a higher speed, by
a special belt u, Fig. 2, from a pulley on the cyHnder shaft.
By these arrangements both the cylinder and doffer revolve
§19 COTTON CARDS 43
with the wire pointing in the opposite direction to the direc-
tion of motion.
10. After making sure that everything is clear of the
cylinder and doflfer and that the belts for driving them are
properly adjusted, the card is started. The cylinder and
doffer are then brushed by means of a brush about 2 feet long
and 3 inches wide, which is held in contact with the cylinder
and doffer wire by the operative and moved from side to
side of the card, thus removing all dust from the interstices
of the wire. The card is then allowed to run a few minutes
to remove from the fiats the dust that has lodged there when
brushing the cylinder and doffer.
Next the card is stopped and the grinder removes such
covers and bonnets as are necessary to be removed. The
grinding roll for the cylinder is then placed in the stands v,
Fig. 2, with the pulley that gives the traversing motion to
the roll on the same side as the main driving belt of the
card. A band for giving the rotary motion is put on the
pulley /a, Fig. 5, of the grinding roll and around one of
the grooves of the pulley e^^, Fig. 2, on the cylinder shaft.
The grinding roll for the doffer is now placed in position in
the stands Vt in the same manner as the cylinder grinding
roll. A band is passed around the pulley /a, Fig. 5, and
around the other groove of the pulley e,e on the cylinder shaft.
The pulley Z^, Fig. 5, on the opposite end of the grinding
roll imparts the traversing motion to the roll /. A band
that passes around the grooved pulley compounded with the
tight pulley on the cylinder shaft passes around the pulley /,
on the doffer-grinding-roll shaft and also over the pulley /,
on the cylinder-grinding-roll shaft, thus imparting motion to
the latter by slight friction only. In some cases an extra
pulley is placed on the shaft of the doffer grinding roll and
a band passed from this pulley around one of similar size on
the shaft of the cylinder grinding roll, thus giving a more
positive traversing motion. The former method of impart-
mg the traversing motion to both rolls is not very satisfac-
tory, as the cylinder roll does not receive as positive a
44 COTTON CARDS §19
motion as it should, owing to the small portion of the pulley
that comes in contact with the band.
It is possible to use one bracket for carrying both the
stripping and the grinding rolls, but it is very inconvenient,
as the wire of the stripping roll should project a short dis-
tance into the wire of the cylinder or doffer, while the surface
of the grinding roll should only lightly touch the points of
the wire on the cylinder or doflEer; consequently, the distance
from the center of the shaft to the surface of the roll will
be different in each case. Even if the two rolls are arranged
at first so that the necessary distances are obtained, the wire
on the stripping roll will wear down more quickly than the
emery on the grinding roll, and thus it will be necessary to
adjust the brackets when changing from one roll to the other.
Consequently, it should be ascertained which bracket must
be used for each purpose, and in operating the card this fact
should be remembered.
OPERATION OF GRINDING
11. Grinding the Cylinder and Doffer. — After
having placed the grinding rolls in their stands, and usually
before the proper bands are adjusted, the grinder proceeds
to set the grinding roll to the wire on the cylinder and
doffer. In performing this operation it is generally first
necessary to use a card gauge, in order to make sure that
neither grinding roll is pressing too heavily on any part of
the cylinder or doffer. After this the proper bands are
adjusted, the card is started and the grinder determines the
actual setting of the grinding rolls to the wire by placing his
ear as close as possible to the point at which the grinding
roll comes in contact with the wire and judging by the
amount of sound that is made whether either grinding roll
is in its correct position. In light grinding, which is
preferable, only a light buzzing sound should be distin-
guished, and care should be taken that this is the same at all
points on the cylinder or doffer. When setting the grinding
rolls, the brackets that support them are adjusted by means
of nuts and setscrews provided for that purpose.
§19 COTTON CARDS 45
During- the grinding operation, the grinding roll of both
the cylinder and the doffer is rotated at a speed of from
800 to 900 feet per minute; the cylinder is making about
2,150 feet per minute, while a point on the surface of the
doffer will move about 1,866 feet per minute in the card
under consideration. The direction of the rotation of the
cylinder and the doffer, and the inclination of the teeth are
such that the grinding roll grinds the back of the teeth. At
the same time, because of its traversing motion, it also
grinds the sides as has been explained. The grinding roll
does not merely touch the wire but produces a slight pres-
sure on it, which tends to force the point of the wire
forwards toward the foundation of the clothing; conse-
quently, if the roll grinds on one portion longer than the
other, the wire will be lower in this place. This is more
liable to occur with the traverse rolls at the edges of the
cylinder and doffer, where the rolls have a slight dwell
during the reversing of the traverse. If possible this
reversing should take place almost beyond the edges of the
cylinder and doffer, and grinding stands are now set wide
enough to allow a longer roll to be used, which permits the
disk to traverse almost off the wire while reversing. After
the card is ground, the grinder removes the grinding rolls
and brushes out the cylinder and doffer clothing, for the
purpose of removing all small pieces of steel or emery
caused by the grinding. After stopping the card, the grinder
removes the belt driving the doffer, makes the necessary
settings, changes the driving belt, and replaces all belts,
bands, and parts that were either removed or changed in
position to prepare the card jEor grinding; he then puts on a
lap and starts up the card.
The length of time required for grinding depends to a
great extent on the condition of the wire, since if the points
of the teeth are dulled considerably, a longer time will be
required than if the clothing is in comparatively good condi-
tion. The degree of coarseness of the emery on the grinding
roll also governs to some extent the time required for
grinding, since coarse emery cuts much faster than fine
46 COTTON CARDS §19
emery. The time required for grinding is also governed by
the amount of pressure exerted by the grinding roll on the
clothing. If the grinding roll is set so that it presses heavily
on the wire, the grinding will be accomplished in less time,
although there is more danger of injuring the wire; such
grinding is known as heavy grinding. If the grinding roll
presses only lightly against the clothing, a greater time will
be required to secure the proper point on the teeth, but there
is less danger of injuring the wire; this method of grinding
is spoken of as light gririding.
The temper of the wire with which the card clothing is set
also affects the length of time required for proper grinding,
since hardened and tempered wire grinds more slowly than
soft wire.
As a general rule it may be stated that from one-half
to one working day, or from 5 to 10 hours, is the usual
time required for properly grinding the cylinder and dofTer of
a card.
The interval between the times of grinding depends some-
what on the product of the card, the condition of the wire,
and the opinion of the person in charge. Generally speaking,
it is advisable to grind frequently and lightly for a long time
rather than at more remote intervals and heavily for a short
time, as the former method is not so liable to heat the wire
and to take out the temper. If the cards are turning off an
average production for medium counts, grinding the cylinder
and doffer once in every 20 or 30 days will be found suffi-
cient. In many mills they are not ground so frequently.
12. Grinding a New Card. — A card that has been
newly clothed requires grinding before being used for card-
ing purposes, and this first grinding operation will be found
to differ somewhat from the usual method of grinding, the
object being to render the surface of the cylinder and doffer
perfectly level at all points. If the fillet is not put on with
a regular tension it is liable to rise, or blister, at places, and
if the tacks that hold it have not been driven with care the
wires around them will be high. Sometimes the edges of
§19 COTTON CARDS 47
the fillet are allowed to overlap slightly or the fillet is
crowded too closely, thereby causing the wire to be higher in
some places than in others. If the card is carefully clothed
these faults should not occur to any extent, but when they do
those wires that are higher than the others must be ground
level with the rest of the surface. A newly clothed card is
first ground with dead rolls, which are left on until the
surface of the wire on the cylinder and doffer is perfectly
smooth; this takes from 3 to 10 days. After the wire has
been ground level by means of the dead rolls, the traverse
rolls are used for the purpose of putting a point on the wire
and are left on about a similar period, the length of time
depending on the temper of the wire and also on the length
of time that the wire has been ground by the dead rolls.
13. Grinding tlie Flats. — The card wire on the flats
requires grinc|ing periodically, and while some portions of
the preceding description and remarks apply to grinding in
general and can be applied to the grinding of the flats, .there
are special features in connection with this process that
make it differ somewhat from the grinding of the cylinder
and doffer. The fact that the flats are arranged in an endless
chain and slide for a portion of their movement on a smooth,
circular arc, while at another portion of their circuit they
are carried over rolls on which they are suspended, prevents
their being driven past the grinding roll at the same speed
as the card wire on the cylinder or doffer. On this account
and also because there are, during the running of the card, a
number of the flats that are performing no actual work for
a considerable length of time, it is customary to grind the
flats while the card is in operation and with the flats moving
at their working speed, which saves a loss of time and pro-
duction. This slow movement of the flats, since only one
flat is ground at a time, causes considerable time to elapse
before all the flats can be brought under the action of the
grinding roll. The dead roll is almost always used for
grinding the flats and is placed in brackets on each side of
the card. These brackets are so adjusted that the roll,
48
COTTON CARDS
§19
when resting in them, will lightly touch the wire of the flats
as they pass from the front to the back of the card; that
is, it grinds the flats while they are suspended by the bracket
over which they move. An arrangement is adopted to
firmly support the flat while it is being ground, and at the
same time hold it in such a position with relation to the
grinding roll that the heel of the flat will not be ground off.
When the flats are at work the heel is closer to the card wire
on the cylinder than is the toe, and if this relative position
Fig. 6
were preserved with regard to the grinding roll, the wire at
the heel would be ground off before the wire at the toe was
touched by the grinding roll.
14. One type of grinding apparatus is illustrated in
Figs. 6 and 7; Fig. 6 shows the grinding apparatus in posi-
tion, while Fig. 7 is a perspective view of some of the
essential parts. The bra'cket a that supports the different
parts is firmly attached to the side of the card, there being a
bracket on each side. Resting against the inclined sur-
face a, of the bracket a is a casting b that carries the
19
COTTON CARDS
49
Fig.
bearings b^ for the grinding roll c. Attached to this casting
is a finger b^ that serves to lock the grinding roll firmly in
position. The casting b is firmly secured to the piece d and
can be adjusted by loosening the nut b^ and turning the set
nut b^, thus moving the grinding roll nearer to or farther
from the teeth of the
flats, as may be de-
sired. A pin di that
is carried by d may
be set in either of
the slots «2, «3 cast
in the bracket a. At
its lower part the
piece d carries the
former d^, which is
so shaped that if it
is pressed firmly
against the end of
the flat, the wire surface of the flat will be presented in such
a position to the grinding roll that the flat will be ground
evenly across its width. These parts are, of course, dupli-
cated on the other side of the card, and rods that serve to
connect the two sides at the points d^, d^ extend across the
card, the entire mechanism being known as the cradle.
The parts mentioned form the principal parts of this
mechanism and its operation is as follows: When the cradle
is in position for grinding, the pin d^ on d projects through
the slot as of the bracket a, but it should be clearly under-
stood that during grinding, d is not supported by the bracket,
since the weight of all the parts is made to bear on the ends
of the flats, which during this time are supported by the
bracket ia^, attached to the bracket a. In this manner,
each flat during its movement from the front to the back of
the card is brought between the bracket a^ and the former d^,
against which it will be rigidly held; the former d^ is milled
in such a manner as to cause the flat to assume its correct
position in relation to the grinding roll and to be held in this
position until it has passed entirely from under the action of
50
COTTON CARDS
19
the grinding roll. When this grinding arrangement is not in
use it may be raised and the pin d^ inserted in the slot a^, thus
bringing all the parts out of contact with the flats; or when it
is desired, all the parts may be removed to another card for
the purpose of grinding.
15. Another device for holding the flats in the correct
position for grinding is shown in Figs. 8 and 9; Fig. 8 shows
the mechanism as it appears when looking at the side of the
card, while Fig. 9 shows certain of the parts as viewed from
Fig. 8
the inside; coasequently, one view is the exact reverse of the
other. These parts are duplicated on each side of the card,
but as they both work exactly alike only one will need a
description. The grinding roll c is placed directly over the
center of the cylinder and rests in the bearing b,, supported
by the stand a, which is firmly attached to the framework of
the card. In the illustrations, the bearing b^ and stand a are
indicated by dotted lines in order to leave an unobstructed
view of the interior parts. Pivoted to the stand a at the
point a, is a casting d., the upper part of which projects
§19
COTTON CARDS
51
sufficiently to come directly over the outer ends of the flat,
and constitutes the former d,. If the flat is forced against this
projecting piece, or former, the teeth will assume the correct
position for grinding. Pivoted to the casting d at the point d,
IS a lever e^ that carries at its outer end a weight ^,, while
the inner arm e of this lever bears against the under side of
the flat. Pivoted to the bracket a at the point d^ is a lever /
that carries a shoulder A that bears against a projection on
the casting d. At its other end, the lever / has a projecting
finger /, that bears against the cam g. Compounded with
Fig. 9
the cam^ is a sprocket gear^,, the teeth of which engage
with the ribs on the backs of the flats.
The operation of this mechanism is as follows: The flats
move continuously, the upper line being face up and moving
in the direction indicated by the arrow. The movement of
the flats causes the sprocket gear g, to revolve on its stud,
and since the cam g is compounded with the sprocket gear,
it will revolve also. The projection /, of the lever / is held
in contact with the face of the cam by the pressure of the
casting of on the shoulder/.; consequently, as the cam revolves
52 COTTON CARDS §19
and one of the high portions of its face comes in contact with
the projection /,, it will force the projection /^ downwards,
and allow it to rise again when one of the low portions of
the face of the cam approaches. This movement of the
lever / causes the casting d and former d^ to be alternately
raised and lowered to a slight extent.
As the flats move in the direction indicated by the arrow,
a portion of the rib of each comes in contact with the upper
surface of the arm e, which tends to raise each flat but is
prevented from doing so by the former d^, consequently, the
flat is practically locked between these two parts, although
its movement in the direction indicated by the arrow is not
prevented. As the former d^ is raised the flat that is thus
locked is carried upwards until it assumes its proper posi-
tion for grinding, which is controlled by the cam g and the
former ^Z^. After the flat has moved suflficiently to be free from
the action of the grinding roll r, the former d^ and arm e are
lowered to allow another flat to be brought into position to
be raised and ground. This operation is continued through-
out the grinding of each flat in the entire set. The lowering
of the former and arm allows each flat to be brought into
position before being raised in contact with the grinding
roll, thus insuring that each flat will occupy its proper posi-
tion before coming under the action of the grinding roll.
16. Owing to the fact that the flat when performing its
carding action is supported at each end only, and also on
account of its length being so much in excess of its width,
there is a tendency for the flats to bend downwards, or deflect,
in the center. The rib forming the back of the flat is so
shaped as to reduce the amount of deflection to a minimum,
but it cannot be altogether overcome. It will thus be seen
that if the flats are ground perfectly level when the wire is
upwards, the surface when reversed, that is with the wire
downwards in position for carding, will be slightly convex
and consequently the ends of the flats cannot be set so close
to the cylinder as their centers. To overcome this difficulty
and also to avoid dirt and pieces of emery dropping on the
§19
COTTON CARDS
53
cylinder, which sometimes occurs when the grinding takes
place above the cylinder, the flats are sometimes ground in
their working position. Such a method is shown in Fig. 10.
In this case, the grinding apparatus is placed at the back of
the card and the flats are ground with their faces downwards
""O^
"=o"
Trrr Tnr
while in the same relative positions as they occupy when
carding. The face of the flat being underneath partly^
prevents broken wires, pieces of steel, and emery from
lodging in the wire and thus being carried around into the
carded cotton and incurring the risk of injuring the clothing.
The grinding roll c is supported by bearings lu that form a
54 COTTON CARDS §19
part of the bracket b, which is fastened to the lower part of
the former d by means of a setscrew b^. The bracket that sup-
ports the bearings is adjustable and may be altered to bring
the grinding roll into its correct position by loosening the
setscrew b, and turning the adjusting nuts on the setscrew b^.
The upper part of the shoe, or former, d, is so shaped as to
give the correct position to the fiat, and at its lower end
is pivoted on the stud «,. Pivoted on this same stud and
connected with the former, is a lever e that is connected to
another lever e^, by means of the link e^; the lever e^ is
pivoted at e^ and carries at its outer end the weight e^.
When the weight is thrown back in the position shown by
the full lines in Fig, 10, it raises the former together with
the bearings for the grinding roll, causing the former to
bear against the end of the flats and thus give each flat the
correct position for grinding as it is brought around by the
sprocket g. When the grinding apparatus is not in oper-
ation, the weight is thrown forwards. By this means the
former, together with the bearings for the grinding roll, is
lowered, and no part is in contact with the flats. The posi-
tions assumed by the different parts when the weight is
thrown forwards are shown by the dotted lines in Fig. 10.
The length of time given to grinding the flats varies for
the same reasons as those given in connection with grinding
the cylinder and doffer, but the intervals between grindings
are longer. It is considered sufficient to grind the fiats every
4 or 6 weeks. It is advisable, but seldom the practice, for a
mill to own a machine for grinding the fiats of the revolving-
top flat cards. When a mill is in possession of such a
machine, it is customary at least once a year to remove the
fiats from each card and to grind them all to exactly the same
gauge, thus insuring that no fiat differs from any other in the
same card owing to the unequal wear either of the wire or of
the ends that rest on the bends.
17. Grinding the Liicker. — The licker seldom requires
grinding, generally only after an accident has happened to it.
When it is necessary to grind the licker, the solid emery
§19 COTTON CARDS 55
or carborundum Trlieel should be used. The licker and
wheel are revolved in such a way as to cause the wheel to
run against the points of the teeth of the licker. After
grinding, the motion of the licker is reversed and the end of
a board moistened with oil and sprinkled with powdered
emery is pressed against the teeth. By this means the teeth
are made smooth. Other methods are sometimes used, such
as applying a soft brick or a piece of sandstone to the back
of the teeth while the licker is revolving in an opposite direc-
tion to its working one.
18. Bnrnisliing. — The card-wire manufacturers supply
what is known as a burnishing brvisli, which is now used
in some mills. The action of plow grinding or side grind-
ing in the manufacture of wire tends to leave the wire rough
at the side, and it is always burnished very carefully before
leaving the factory. As it wears down, parts of the wire are
reached that have either become rough or were not acted on
by the burnishing brush in the manufacturing of the wire.
The burnishing brush is therefore used in the mill to burnish
the wire on the cylinder, doflEer, and flats. It is somewhat
the same as the stripping roll, but has absolutely straight
wire about f inch in length set loosely in the foundation.
The brush rests in the stands usually occupied by the grind-
ing roll. It is set into the card wire about i inch and makes
about 600 revolutions per minute; its outside diameter is
7 inches. It is usually left in operation for a whole day or
even longer.
When burnishing the wire on both the cylinder and the
doflfer it is customary to run them at a very slow speed.
This is accomplished in the card under description as follows:
A band pulley 14^ inches in diameter having three grooves
on its face is compounded with a 20-tooth barrow gear
by means of a sleeve. The regular barrow pulley and
barrow gear are removed from the barrow stud and the
band pulley and gear substituted. The main driving belt
runs on the loose pulley, on the edge of which is a
groove 20 inches in diameter. In this groove a band is
56 COTTON CARDS §19
placed that drives the band pulley on the barrow stud at
about 220 revolutions per minute. The additional grooves
in this pulley, by means of bands, drive the burnishing
brushes. The speed of the doffer by this method is about
23 revolutions per minute, and as it carries a pulley 11 inches
in diameter that drives an 18-inch pulley on the cylinder
shaft, the cylinder will rotate at about 14 revolutions per
minute. The circumferential speed of the burnishing
brushes is about six times that of the cylinder.
SETTING
19. The setting of the different parts of the card requires
careful attention and is one of the most important points in
the management of the card room. Owing to the wear of
the wire in grinding and the wearing of the journals of the
shafts carrying the cylinder, doffer, and licker, there is a
constant tendency for the wire teeth of the different parts of
the card to separate and thus increase the distance between
their surfaces. This calls for a readjustment of the various
parts, which is known as setting.
The principal places where setting is required are as fol-
lows: between the cylinder and the flats, between the licker
and the cylinder, and between the doffer and the cylinder.
Other places for setting are between the mote knives and
the licker, between the feed-plate and the licker, between the
cylinder screen and cylinder, between the licker screen and the
licker, between the back knife plate and the cylinder, between
the front knife plate and the cylinder, between the fiat-strip-
ping comb and the flats, and between the doffer comb and the
doffer. In order to determine when these parts require set-
ting, it is sometimes necessary to remove certain covers or
bonnets and insert gauges, while in other cases the proper time
for setting is determined by examining the work delivered by
the card, a method requiring an experienced eye. The
intervals at which cards are set vary in different mills, but
the parts that contain the clothing are usually set directly
after grinding, while the time for setting the other parts is
§19 COTTON CARDS 57
governed largelj'^ by the amount of work done by the card
and the stock being used or to be used.
20. Gauges. — The exact setting, or distance between
certain parts, of the card is determined by the use of gauges;
two, and in some cases three, kinds are used. The first one
is about 9 inches long and If inches wide and contains four
leaves pivoted together. These leaves are made of thin
sheet steel and are usually tt^, tijW, to oir, and liwo inch
thick, respectively. The second gauge, which is used exclu-
sively for flat setting, consists of a strip of sheet steel about
2i inches long and li inches in width bent at right angles
about 2 inch from one end, with a handle attached to this
end. The other end is the part used for setting and is
usually Tofo", 1000, or io*oo inch thick. The third gauge
consists of a quadrant or semicircle mounted on a shaft and
is used for setting the top of the cylinder screen to the cylin-
der and licker, and also in some cases to set the licker screen
to the licker. The curvature of this gauge corresponds to the
curvature of the licker. Card gauges are spoken of in the mill
as being of a certain number, thus a gauge toVo inch thick
is termed a No. 7 gauge, while a gauge looo inch thick is
termed a No. 10 gauge.
Since the leaf and fiat gauges are very thin, they are
easily damaged, and in this condition are of little use, pro-
ducing faulty settings; consequently, great care should be
used to prevent the faces becoming dented, bent, or injured
in any way. As the efficiency of the card depends on the
proper settings, it will be seen that any defect in the gauge
will injure the quality of the production of the card. In
many cases poor work results from faulty settings or
poor gauges.
21. Setting the Flats. — In order to make it possible
to set the teeth of the flats the required distance from the
teeth of the cylinder it is necessary that some means be
adopted by which the flats may be raised or lowered as
desired. The manner of accomplishing this will be found to
differ on different makes of cards; one method is shown in
58
COTTON CARDS
§19
Fig. 11. In this figure a portion of the cylinders of the card,
the arch g, and the fiats / supported by the flexible bend h are
shown. It should be understood that there is a flexible bend
similar to h on the other side of the card and that the ends
of the flats rest on this bend in a similar manner to that
shown in Fig. 11. The bend h is supported by brackets,
which in some cases are composed of two parts h^Ji^. In
Fig. 11
Fig. 11, the outer portion h^ is shown in dotted lines. The
inner portion //, is so made that a projecting lug h^ fits into a
hole in the bend and securely holds it in position. The
part h^ is supported by a screw that passes through the
rib^i of the arch and carries two set nuts h^Ju, one above
and one below the rib. The bracket is also further held in
position by means of the screw //,, which passes through a
slot in the bracket and enters the arch of the card. It is by
§19 COTTON CARDS 59
raising or lowering the bend // by means of the bracket //,
that the flats are raised or lowered as desired. There are
five of these brackets on each side of the card, and when
setting the flats care should be taken that all the brackets
are properly adjusted. When setting the flats, the screw /^
and nut Ju are loosened and the flats raised or lowered by
turning the nut Ju either down or up, respectively. After
the flat has been set in the desired position, the screw h^ and
the nuts //s, h^ are firmly secured, thus holding the bracket
and bend securely in their proper positions.
22. Another arrangement for setting, or adjusting, the
flats is shown in Fig. 12 {a) and {b) , of which {a) is a plan
view, partly in section, and {b) a sectional elevation. The
flats are supported by the flexible bend in the usual manner,
but the method of supporting the flexible bend is a radical
departure from the one just described, the only resemblance
being that both have five setting points on each side of the
card. The shell of the cylinder covered with fillet is shown
at w, while w^ represents the flat, which is supported by the
flexible conical bend w^, and this in turn is supported by
the rigid conical bend W:, instead of brackets. The bend w^
rests on the arch w^ of the card. It can be seen by referring
to the figures that the under surface of the flexible bend is
beveled and rests on the beveled surface of the rigid bend;
consequently, when the bend w^ is forced in toward the cylin-
der the bend w^ must rise, while on the other hand if w^ is
forced outwards the bend w^ must fall, thus raising or lower-
ing the flats as may be desired. The bend w^ is operated
by a screw w^ that projects through this bend into the arch of
the card and is held in place by the binding nut w^. On the
inner side of the bend W:, is a toothed nut w, that serves as
a binding nut and also as a device for forcing the rigid bend
away from the cylinder. On the outer side of the bend
is a nut w^ that serves as an index nut, a binding nut, and
also as a device for forcing the rigid bend in toward the
cylinder. The toothed nut w., is operated by a key w^ that
has a fluted, or toothed, portion to fit the teeth of the nut w,.
60
COTTON CARDS
§19
§19 COTTON CARDS 61
When it is desired to lower the flats, or set them closer to
the cylinder, the key w» is inserted in a hole in the rigid
bend and engages with the teeth of the nut w,. The index
nut is moved out on the screw and then the toothed nut is
tightened by means of the key, thus forcing out the rigid
bend and binding it firmly in position. When it is desired
to raise the flats, the toothed nut is loosened and the index
nut moved in, thus forcing the rigid bend in until the desired
position is reached, after which the toothed nut is again
tightened. The index nut is provided in order that the
person making the adjustment may tell at a glance just how
far the flats are moved.
23. The flats are set by means of the flat gauges
described, while the card is stopped, and preferably when
other machinery in the room is also stopped, so as to pre-
vent any vibration of the floor. In order to provide a blank
space in which to insert these gauges, it is necessary to
remove certain flats from the chain of flats above the cylin-
der. Two methods of removing these flats are followed,
depending on the method of setting that it is intended to
adopt. In those cards constructed with five setting points
on each side of the card, it is common to use five flats for
setting purposes, a flat being selected that stands almost
immediately above each setting point. The flats on each
side of the setting flats, as they are called, are removed,
making it possible to slip in a gauge on either side of the
setting flat; thus, there are ten flats in all removed. A short
shaft carries the worm-gear /,2 and the worm /,3, Fig. 2,
through which the flats are driven; on this shaft a crank is
placed and used to turn the flats while setting. By means of
this crank the flats are turned until each of the five setting
flats comes directly above a setting point, and they remain in
that position until the setting of the flats is completed.
Another method is to remove a flat on each side of one
setting flat only, or sometimes two setting flats. This gives
but one or two flats that are used for setting purposes, and
as there are five setting points on the flexible bend, the chain
62 COTTON CARDS §19
of flats must be turned several times in order to bring these
setting flats directly over the places where the gauges are
inserted. Advantages are claimed for each system, but on
the whole there is less work and quicker setting when using
five setting flats.
The side of the flat used for setting purposes is the heel,
which is the side nearest the wire on the cylinder, being about
ToT inch nearer than the toe. Having brought the setting
flats into the correct position over the setting points, the
gauge is inserted first between the flat and the cylinder above
the central setting point, and the proper adjustment made, as
has been described. In setting a flat it is only possible to
set one end at a time. The end that is being set, however,
should be held firmly in position on its bearings with one
hand while the gauge is moved back and forth across the
card between the flat and the cylinder with the other hand.
Owing to the width of the card it is impossible to move the
gauge the entire length of the flat; consequently, one side is
set temporarily and then the other side is set in a similar
manner, after which the first side set should be tested and
also the second side set to make sure that the flat is in the
proper position. When both ends of the central flat have
been set, the flat at the extreme front of the card is usually
set next, at both ends; then both ends of the flat nearest the
rear of the card are set, and then the two intervening flats.
In setting flats there should be a certain amount of friction,
or resistance, felt when moving the gauge along between the
flat and the cylinder.
The settings mentioned are only temporary settings, and
after the adjustment of the flats the brackets should be
seciired and the settings again tested, in order to make sure
that the proper spaces exist between the cylinder and the
flats. The cylinder should now be slowly revolved, the flats
at the same time being moved, and if any rustling sound
is heard it is an indication that the wire surface of the flats is
coming in contact with the wire surface of the cylinder at
some point, in which case the flats should be set farther from
the cylinder at that point.
§19
COTTON CARDS
63
64 COTTON CARDS §19
The flats are usually set about il uu inch from the cylinder at
the heel of the flat. The flats at the front of the card should
be set the closest to the cylinder, while the space between
the flats and the cylinder should gradually increase toward
the back. If a No. 10 gauge is used, the flats at the back
are set loosely to the gauge; those at the top and center, a
little closer; while those at the front are set still closer.
24. Setting the Liicker. — The licker is mounted on
movable bearings ti'.o resting on and secured to the frame-
work, or base, of the card as shown in Fig. 13. There is a
lug zc\t on the arch of the card, through which an adjusting
screw Z£'i2 for adjusting the licker to the cylinder is passed.
By loosening the nuts ze'.s, z^'ie, which securely hold the
bearing to the framework, and by operating the adjusting
nuts tt',3, tt',4 on the adjusting screw 7i\2, the licker may be
moved nearer to or farther from the cylinder, as desired.
The leaf gauge is used for this setting and the licker is
generally set to the cylinder with a No. 10 gauge.
25. Setting tlie Doffer. — The doffer is also mounted
in movable bearings Wi,, Fig. 14, which rest on the frame-
work of the card and are securely fastened to it by the bolts
and nuts u\s, u\^. An adjusting screw u\_o connects the
bearing of the doffer with a lug ti'^, on the arch of the card.
When it is desired to set the doffer, the nuts u\s, u\^ are
loosened, and the doffer can then be set to the desired
position by means of the adjusting screw zc^c and the
nuts a'22, zfas. The doffer is usually set to the cylinder with
a No. 5 or No. 7 leaf gauge by inserting the gauge
between the doffer and the cylinder where they are in
closest proximity. When a No. 7 gauge is used, the doffer
is usually set tight to the gauge. After attaining the proper
distance between the doffer and the cylinder, the nuts zi\^, u\^
are tightened, as well as the adjusting nuts w^., ^',3. The
position of the doffer with relation to the cylinder is an
important matter and should receive careful attention. If
the doffer is set too far away from the cylinder, a patchy
or cloudy web will result, owing to the doffer not taking
19
COTTON CARDS
65
Fig. 14
66 COTTON CARDS §19
the fiber from the cylinder regularly and thus allowing the
wire of the cylinder to fill up.
The mote knives are carried by two brackets, one at either
end, and can be adjusted in regard to the relative distance
between their blades and the surface of the licker as
described in connection with the construction and operation
of the various parts of the card. These knives are set to
the licker by means of the leaf gauge and the number of the
gauge varies from 12 to 17.
26. Setting the Feed-Plate.— The feed-plate b rests
on the frame of the card, as shown in Fig. 13, and is fastened
to it by means of the bolts and nut x. When it is desired
to set the feed-plate b to the licker c, the nut x is loosened
and the plate moved nearer to or farther from it by means of
the adjusting screw x^ and the nuts x^, x^. The screw x^
passes through a lug x^ on the framework of the card and
into the feed-plate. The leaf gauge is also used to make
this setting and is inserted between the licker and the face of
the feed-plate. The number of the gauge varies from 12 to 20.
27. Setting the Cylinder Screen. — The cylinder
screen is made in two sections in the card under description
and these sections are fastened together by two staple-shaped
bolts, one on each side of the card. These bolts pass through
the framework of the card near the floor. Inside the frame-
work of the card on each side is a thin metal arch adjusted
so as to be in close proximity to the end of the cylinder.
When the screen is in position, it is between, and attached
to, these arches, thus forming a casing for the lower portion
of the cylinder. The screen is held in position by a number
of bolts passing through the side arches of the screen. There
are a number of slots in the circular arches of the screen
through which the gauge can be inserted in order to obtain
the proper distance between the cylinder and the screen.
The nuts on the bolts that hold the screen in position are
on the outside of the arches. When it is deemed necessary
to set the screens, the doors on the sides of the card are
removed to give access to the nuts on the bolts and to allow
§19 COTTON CARDS 67
a gauge of the proper thickness to be inserted in any of the
slots of the screen arch. The screen is raised or lowered to
the proper position as determined by the gauge and the nuts
are then tightened, thus holding the screen in position. The
screen is set farther from the cylinder at the front than at
any other point, the distance being about .25 inch, while the
screen at the center and back is set about .032 inch from the
cylinder. This arrangement prevents the ends of the fibers
that have been thrown out by centrifugal force from coming
in contact with the front edge of the screen and thus being
removed from the cylinder as fly.
28. Setting the Thicker Screen. — As the licker and
cylinder screens are very close to each other at their nearest
point, and as the front end of the licker screen must be set
only a short distance below this point, it is nearly impossible
to make an accurate setting with the licker in position. The
best method is to remove the licker and use a quadrant
gauge, the curvature of the outside surface of which should
correspond exactly to the curvature of the surface of the
licker. This gauge is mounted loosely on a shaft of exactly
the same bore as the licker shaft. The ends of the shaft
rest in the licker bearings and the screens are set to the
proper distance from the quadrant gauge by sliding the
quadrant along the shaft. The front edge of the licker screen
at the point where it is hinged to the cylinder screen is usu-
ally set about .011 inch from the licker. The nose, or por-
tion of the licker screen with which the fibers first come in
contact, is set iV to i inch from the teeth of the licker,
according to the amount of cleaning action desired at this
point and the staple of the cotton being used. Setting the
screen farther from the licker at the nose than at the front
allows the fibers to be drawn gradually into a more compact
space and presents a more even layer of fibers to the action
of the wire on the cylinder.
29. Setting: the Back Knife Plate. — The back knife
plate ^«, Fig. 13, extends from the licker cover, or bonnet,
upwards to the fiats and corresponds in curvature to the
68 COTTON CARDS §19
curvature of the cylinder. This plate is fastened to a circu-
lar bend x^ by means of two screws at each end, and the
bend is attached to the adjustable bracket of the licker by
means of two setscrews Xo, x-,; consequently, when the licker
is adjusted the back knife plate is adjusted, or it can be
adjusted independently by means of the setscrews x^, x-,.
The plate is set to the cylinder to about a No. 17 leaf gauge
at the lower edge and a No. 32 at the upper edge. This
allows the fibers to free themselves and stand out a little from
the cylinder before coming in contact with the flats.
30. Setting the Front Knife Plate. — The front knife
plate ^11, Fig. 14, extends from the cylinder door above the
dofier to the point where the flats first leave the cylinder.
The amount of flat strippings depends to a great extent on
the setting of this plate. The plate is fastened to a circular
bend x^ by means of two screws at each end, and can be
adjusted by means of the bracket ^-9, the adjusting screw jt',o,
and nuts ;f„, x^^; or it can be adjusted to a certain extent by
the setscrews jr,,, x^^. The screw x^^ passes through an
arm x,^ of the circular bend x^, while both screws ;i:,3, x^,.
come in contact with the arm x^^ of the bracket x^; thus by
loosening one screw and tightening the other the plate can
be adjusted. The front knife plate is also set with the leaf
gauge, its distance from the cylinder at the lower edge being
about .017 inch. The space between the upper edge of the
plate and the cylinder depends on the amount of waste that
it is desired to remove as fiat strippings, but the usual
setting is about .032 inch. If the plate is set farther from
the cylinder, more and heavier strippings will be made, and
if moved too far away, the strips will form one continuous
web instead of being connected by merely a few fibers. If
the plate is set too close, some of the short fibers and dirt
removed from the cotton by the flats will in turn be taken
from the flats by the knife and carried around by the cylin-
der, thus producing bad work.
31. Setting the Stripping Comb. — The flat stripping
comb is mounted on two arms, as described in connection
§19 COTTON CARDS 69
with the construction and operation of the various parts of
the card. There is one nut on each side of the comb at each
end. The comb is set by adjusting the nuts on the arms
when it is at the lowest part of its swing, with its teeth
opposite the toe of the flat. Sometimes it will be necessary
to try two or three flats before the comb is set in its proper
position. The distance between the toe of the flat and the
comb is determined with the leaf gauge and is usually about
.007 inch; although this setting should be close enough to
allow the comb to remove the strippings from the flats, it
should not be so close that the comb will strike the wire
and damage it.
32. Setting tlie Brusli and Hackle Comb. — The
brush for stripping or brushing out the dust, etc., from
between the interstices of the flats is set so that the ends of
the bristles do not quite reach the foundation of the fillet on
the flats. The brush has longer bristles near its ends, in
order to brush the ends of the flats where they rest on the
flexible bends, so as to keep them clean and preserve the
accuracy of the settings.
The hackle comb is set so that the needles, or teeth, of
the comb project for a short distance into the bristles of the
brush, in order that all the waste may be removed from
the brush.
33. Setting the Doffer Comb. — The doffer comb is set
in a manner similar to that in which the doffer and licker are
set. The comb is mounted on sliding bearings fastened to
the framework, or base, of the card by means of bolts. A
setting screw is fastened to the bearing of the comb at each
side and passes through a lug that is fastened to the frame-
work of the card. When it is desired to set the comb, the
nuts on the bolts that attach the bearings to the framework
are loosened and the comb drawn nearer to or farther from
the doffer by means of the adjusting nuts on the setting
screws, as described in connection with the setting of the
doffer and feed-plate. When the proper distance is obtained,
all the nuts are tightened. The comb is usually set to the
70 COTTON CARDS §19
doffer at the point where they are in closest proximity with
a No. 7 leaf gauge.
The doffer comb, in addition to being adjustable as to its
distance from the doffer, is adjustable as to the position of
its stroke, which is changed by altering the relative positions
of the comb and the eccentric from which it receives its
motion. If the web should follow the doffer instead of being
removed by the comb, the position of the stroke should be
lowered; while if the web sags between the doffer and the
trumpet, as it sometimes does, owing to atmospheric changes,
etc., the position of the stroke should be raised.
The settings given are used only as a basis. The settings
of the various parts of the card vary according to the stock
being used, the quality and kind of finished work, and the
opinion and judgment of the superintendent or overseer in
charge.
It is sometimes desirable to make a setting for which
there is no gauge of the proper thickness at hand. In such
cases it is customary to use in combination two or more
of the leaves of the leaf gauge; for instance, if it is desired
to set the mote knives to the licker with a 17 gauge and
no such gauge is available, the 10 and 7 leaves of the leaf
gauge can be used together.
MANAGEMENT OF ROOM
34. In the management of cards many points should be
watched, but more especially those that have for their
objects: (1) the production of good work; (2) turning off
as large a production as is consistent with the quality of the
work required; (3) economy by avoiding unnecessary waste
and keeping down the expenses of wages, power, supplies,
etc.; (4) maintaining the machinery in good condition.
35. Quality of Production. — With reference to the
first requirement, it may be said that good work is usually
judged by examining the web from the front of the doffer.
By withdrawing a portion of it as the card is running and
§19 COTTON CARDS 71
holding it to the light, the foreign matter and also the neps
remaining in the cotton can be observed. If it is the opinion
of the overseer that from the grade of stock being used and
from the speed of the card such work is not suilficiently good,
the card should be examined to ascertain whether it requires
grinding or setting. An allowance should be made if the
card is examined just before the time for stripping, as at
that time the card wire is usually so full of dirt that more or
less necessarily passes through, although this is to some
extent an indication that stripping should be performed more
frequently. In order to test whether wire requires grinding,
or in other words whether it is sufficiently sharp to do its
work, it is customary to rest the fingers of one hand on the
face of the wire when the card is stopped and by drawing
the thumb against the points judge of their sharpness by
the amount of resistance that is felt. Dull wire allows
the thumb to pass with the least resistance. Should the wire
show a glistening surface or appear bright on the end of
each point, it may generally be considered dull, although
this is not an infallible test, owing to the direction in which
the light strikes the wire.
The cotton should leave the doffer in a level sheet, free
from cloudiness and having good sides. The intermittent
clouded effects and flock sides formerly so common are not
met with so frequently in revolving flat cards. Sometimes
these defects are caused by cotton lodging in some part of
the card, more especially in connection with the screens or at
the point where the cylinder and the doffer meet, until there
is sufficient to be pulled through in one lump by the wire.
Another test is to examine the fly underneath the card and
if it is found to contain an appreciable amount of good fiber,
it indicates that the screens need adjusting. In case of the
feed-plate, and more especially where two feed-rolls are
used instead of a feed-plate and a feed-roll, plucking some-
times occurs and causes a cloudy effect. Cotton lapping on
the doffer instead of being stripped off by the comb is trouble-
some, more especially when the rooms are allowed to get
cold during frosty weather.
72 COTTON CARDS §19
36. Quantity of Prodiiction. — The second point of
management is that of obtaining as large a production as
possible. This can be obtained by reducing to a minimum
the time when the card is stopped for stripping, grinding, or
setting, also by the attendants putting on the new lap as
soon as the old one has run off and by not allowing the card
to remain stopped on account of the end having broken
down in front. When these economies of time have had
attention, the only other method of increasing the produc-
tion is to speed up the card, which is usually done by
increasing the size of the barrow gear. The increase in
the speed of the doff er is in direct proportion to the increase
in the size of the gear. There are many cards at work pro-
ducing 1,000 pounds per week of 60 hours, and the produc-
tion of a card varies from this down to 200 or 300 pounds
per week. A good speed for American cotton when intended
for 32s yarn, carding 800 pounds per week, is about 122
revolutions per minute of a 24-inch doffer for a 60-grain
sliver. When carding Egyptian cotton intended for 60s to
90s yarn and carding about 500 pounds in a week of 60
hours, a good speed for a 50-grain sliver is about 10 revolu-
tions per minute. With sea-island cotton intended for yarn
finer than 100s, carding 250 to 300 pounds per week and pro-
ducing a 35-grain sliver, a good speed for the doffer would
be about 6i to 8 revolutions per minute. With a 27-inch
doffer the number of revolutions would be proportionally
smaller. The maximum average stoppages during a week
for stripping, grinding, cleaning, and all sundry repairs
around the card ought not to exceed 10 per cent., and with
care this might be reduced to li per cent.
37. Economy. — The third point in the management of
card rooms is that of economy; this is most important in
respect to the amount of waste produced. The largest per-
centage of waste in any part of a card is in flat strippings and
amounts to about li per cent. The next is the amount of
fly from beneath the licker and cylinder, amounting to an
average of 1 per cent. The cylinder and doffer strippings
§19 COTTON CARDS 73
together amount to about I per cent., making a total loss at
the card of about Si per cent., or somewhat over Si per cent.*
if the card sweepings are taken into account. No allowance
is here made for the unavoidable loss in the weight of the
cotton due to its drying in the hot card room. For fine
yarns or particular work these figures may be increased, and
for coarse yarns and inferior product, decreased.
In order to secure economy in the flat strippings the front
plate should be set in such a manner that the flats will not take
out any good cotton. When it is set otherwise, the strippings
from the flats seem to be connected by a thick film of good
cotton that is generally sold together with the strippings as
waste. As previously described, this film can be reduced
until the strippings cling together by means of a few fibers
only. Beyond this point the only method of reducing the
amount of flat strips is to lessen the speed at which the flats
move, although this is not advisable, as it deteriorates the
quality of the work by not removing so much foreign matter
from the cotton. The flats will also be connected by a thick
strip of cotton if the heel and toe are not preserved in grinding.
The principal method of reducing the percentage of the
cylinder and doffer strippings is to reduce the number of strip-
pings, which is undesirable unless it is desired to lower the
quality of the work. The fly beneath the card can either be
increased or decreased according to the style and setting of
the screens under the card and the setting of the mote knives.
Tests have been made with cards without screens and it is
found that they make about ten times as much fly as cards
with screens. Both the knives and the triangular bars that
form the screens should be so arranged that they will give
free passage for any dirt that tends to lodge there and also
to allow the ends of the fibers to be combed or brushed over
the edges of the knives, but the spaces between the bars of
the screens should not be so large as to allow the fibers
themselves to be driven through.
38. Proper Care of Macliinery. — The fourth point in
the management of cards, namely, keeping the machinery in
74 COTTON CARDS §19
good condition, necessitates first of all proper oiling. All
parts of the card that are in contact with swiftly moving
parts, such as the mechanism in the comb box, the cylinder-
shaft bearings, and licker-shaft bearings, should be oiled
twice daily; certain other parts that do not revolve so rapidly,
for instance the doffer, calender-roll shaft, side shaft, coiler,
and all idler pulleys and gears, should be oiled daily; while
once a week, generally Monday morning, every moving
part of the card should be oiled. Cylinder, licker, and doffer
bearings should be filled with tallow, having a small hole in
the center so that it will allow the oil to run directly on the
shafts and provide a reserve of lubrication that will melt in
case of a hot bearing. In oiling the bearings of the doffer
and cylinder, care should be taken not to allow the oil
to get on the heads of the cylinder or doffer, since in this
case it is apt to come in contact with and spoil the clothing.
Care should also be used in oiling the traverse grinder that
the oil does not fly on to the clothing.
The cards should be kept free from fly and dust and it is
usually the custom to clean them after the stripping process.
An opportunity should be given at least once a week,
usually on Saturday morning, for the cards to be stopped
2 hours for cleaning purposes, at which time a more thorough
cleaning is given to all parts than can be given while the
cards are running. About once a month the coiler should be
taken apart and cleaned, the feed-roll taken out and cleaned,
the licker picked free of all foreign substances, and all belts
carefully looked over. The belts should be cleaned and
dressed as often as it is necessary. Fly from under the card
is generally removed twice a week, and any cotton or fly
attached to the screens should be picked or brushed off at
the same time. The roll on which the lap rests should not
be allowed to wear too smooth, but should be painted with
some rough composition, such as paint mixed with sand, that
will give it a rough surface and prevent the slipping of the
lap. The cylinder and licker screens should be taken out
periodically and cleaned, a good practice being to polish them
well with black lead, which makes them dry and smooth.
§19 COTTON CARDS
75
The inside faces of the front and back knife plates and the
bonnets of the doffer and licker should also be polished with
black lead.
After disturbing the settings of a card in any way, the
cylinder and licker should be turned around by hand to make
sure that there are no parts rubbing. After setting or grind-
ing, and whenever there has been occasion to loosen screws,
nuts, or other parts of the card, these parts should all be
gone over to make sure that they are tight before starting
the card.
39. The speeds of the different parts of the machine are
taken by a speed indicator. The doffer, however, has so
few revolutions per minute that its speed can be ascertained
by watching a point on its circumference and counting the
number of revolutions it makes.
There should be only sufficient draft between the lap roll
and feed-roll, the doffer and the bottom calender roll, the
bottom calender roll and the calender roll in the coiler to
take up any slack that may occur between these parts. Any
excessive draft causes the sliver to be unevenly drawn, thus
making thick and thin places in the yarn.
DRAWING ROLLS
COMMON ROLLS
BOTTOM ROI.I.S
1. Introduction. — The principle of roll drafting is the
most important feature of parallelizing and attenuating
machinery and in the production of good yarn. Therefore,
the construction of drazving rolls and various points
pertaining to them justify a detailed description. Dl•a\^^ing
rolls, of which there are two kinds — common and metallic —
are placed in pairs one above the other, the lower ones being
driven positively by means of gears; the upper ones, when
common, are driven by frictional contact from the bottom
rolls, while those that are metallic are driven positively, as
will be described later.
2. Construction. — Fig. 1 shows a set of common
rolls consisting of three pairs, a being a bottom roll and a,
a top roll. The bearings of the bottom rolls rest on stands b
that are bolted to the roll beam c. The construction of the
bearings for the rolls and the method of adjusting them in
order to obtain the desired distance between any two pairs is
fully explained in later pages. Fig. 2 shows a cross-section
of the bottom roll a. Fig. 1. These rolls are almost
always constructed of steel, and are fluted; that is, grooves
are cut lengthwise in the surface of the rolls at certain
intervals. These flutes aid the bottom rolls in obtaining a
better grip on the cotton as it passes between them and the
top rolls. The grooves, as shown in Fig. 2, are not perfectly
For notice of copyright, see pa£e immediately following the title page
§20
DRAWING ROLLS
§20
wedge-shaped, nor do they end in a knife edge, although the
face of the roll carries almost a square corner on each side
of a flute. A groove is a little less in width at the bottom
xu'*^v-i
Fig. 1
than at the top, while the number of flutes for the various
rolls increases with the diameter of the rolls and with the
fineness of the work for which
the machine is intended. For
example, a roll li inches in
diameter will contain more
flutes than a roll 1 inch in diam-
eter, while a roll intended to be
run on a machine that deals with
the stock in the later processes
will contain more flutes than a
roll of the same diameter that is
intended to be run on a machine
dealing with the stock in the
earlier processes, since the cotton in the former case is not
in as bulky a condition.
Rolls are often made with the flutes unevenly spaced; that
is, the distance between two flutes in one place is different
Fig. 2
§20 DRAWING ROLLS 3
from the distance between two flutes in another part of the
same roll. This is done in order to prevent the cutting of
flutes in the top leather roll that would correspond with those
of the bottom roll, which would be detrimental to good work.
It is also necessary to have these rolls refluted at times, since
the constant action of the cotton on the flutes will wear them
very smooth on the edges and thus prevent their gripping
the fibers. It is important not to have the roll stands for the
bottom rolls too far apart, since in this case the roll, due to
the weight of the top rolls and other weight placed on it,
will be deflected out of a straight line, causing the roll to
run untrue and resulting in poor work.
The bottom rolls are almost always case-hardened in the
necks, or bearings, and in some cases throughout. They are
thus rendered stiffer and stronger, which makes them more
capable of resisting torsion, the necks wear longer, and the
flutes are not so liable to become damaged by an accident or
by carelessness. The preservation of the necks is also
assisted by inserting brass bearings into the roll stands.
3. Method of Connecting Sections. — The bottom
rolls are built in sections varying from 13 to 24 inches in
length, each section being joined to the next by means of a
squared end of one section fitting into a squared recess in
another section. It is of the utmost importance that these
ends shall fit into their sockets accurately, and if they become
worn, as is sometimes the case with the older makes of rolls
composed of soft metal, they should be resquared. It will
easily be seen that in a frame 20 or 30 feet long having a
number of these joints in each roll, a minute fraction of play
at each socket will become an important item in the whole
length of the frame and tends to produce what is technically
called ad yarn. When the rolls are removed in sections,
care should be taken that each section is replaced in the
position from which it was taken. In order to make this
convenient, the end of each section is numbered, the num-
bers generally running consecutively from the driving end
of the machine.
DRAWING ROLLS
20
TOP ROI.LS
4. Construction. — Top rolls are constructed of iron
and are made in short lengths, a portion of their circumfer-
ence being afterwards covered with cloth and leather. That
part of the roll that is used for drawing the cotton, which in
common top rolls is the leather-covered portion, is known
as the doss and is always of a larger diameter than the
remainder of the roll. Top rolls may be made with one or
two bosses, being known as si?igle-boss and dotcble-boss,
respectively; the boss in both single- and double-boss rolls
may be detachable. When the boss of a roll is detachable,
the roll is known as a loose-boss, or shell, roll; when the boss
is not detachable, the roll is known as a solid roll. In loose-
boss rolls the part that is detachable is known as the shell of
the roll, while the part on which the shell rests is known as
the arbor.
§20 DRAWING ROLLS 5
Fig. 3 shows the different styles of top rolls. A solid roll
having a single boss is shown at (a), a longitudinal section
of this same roll being shown at (d); a solid roll with a
double boss and a longitudinal section of the same roll are
shown at (c). A loose-boss roll having only one boss and a
longitudinal section of the same roll are shown at (d) and
((?), while a loose-boss roll with a double boss and its
longitudinal section are shown at (/) and {£-).
5. Single- and Double - Boss Rolls. — In certain
machines that utilize drawing rolls there is one roll to
every delivery; that is, all the fibers passing one roll are
gathered together into one sliver at the front; therefore, for
these machines the single boss is preferred. In certain
other machines there are always two or more ends coming
from each roll, so that the tloxible-boss construction is
preferable. Sometimes one end comes from one boss; in
other cases two ends come from one boss; while in still
other cases three ends are found coming from each boss of
a double-boss roll, making six from the roll.
The advantage of double-boss over single-boss rolls is
due to the fact that there are less weights, hooks, and wires
on a machine equipped with double-boss rolls and, therefore,
the machine can be better and more easily cleaned. The
cost of construction is also less with double-boss rolls, and
the weighting is simpler. It also requires less oil, thus
reducing the probability of staining the cotton. Another
advantage that is claimed for double-boss rolls with the
loose boss is that any slight variation in the diameter of
either boss, as compared with the other, is offset to a certain
extent, on account of the independent motion of each boss.
One great advantage that the single-boss roll has over
the double-boss roll is that more even yarn is produced with
the former, as each end or group of ends is treated inde-
pendently of the others.
6. Solid- and Loose-Boss Rolls. — Solid-boss rolls
are gradually passing into disuse except for the back rolls
of frames, being replaced by rolls with loose bosses. With
6 DRAWING ROLLS §20
a loose-boss roll only the shell revolves, consequently the
neck and ends do not need oiling. When it is desired to oil
the roll, the shell is removed and a few drops of oil placed
on the arbor. With such a construction, especially when
such thorough lubrication can be obtained, it is very easy for
the shell to revolve and there is also little danger of oil get-
ting on the cotton.
The portion of the arbor enclosed by the boss is barrel-
shaped, being large at the center and tapering off toward
each end. This construction reduces the friction by reducing
the bearing surface of the shell on the arbor, and the oil
tends to run toward the thickest portion of the arbor, thus
insuring proper lubrication and preventing the leakage of oil.
Rolls are also constructed on this principle with the shell
having ball bearings on the arbor.
COVERING TOP ROLLS
7. As two metal rolls revolving in contact would tend to
crush the delicate cotton fibers, a leather covering is pro-
vided for the top rolls of the common type. The iron sur-
face of the roll is first covered with a specially woven woolen
cloth, which is cemented to the roll, giving a good, elastic
foundation. When a thin leather covering that fits very
tightly is drawn over this foundation, the roll is capable of
gripping the fibers and, owing to the yielding quality of the
leather and cloth, does not damage them.
In order to secure the best results, the greatest care should
be exercised in covering the roll, and the best stock should
be used. The production of an even thread depends more on
the quality of the cloth and the leather, the manner in which
it is applied, and the care of the rolls in the machine than
on any other factor in the process of manufacture, with the
exception of the grade of cotton used. Various substitutes
for woolen cloth and lambskin or sheepskin have been tried
from time to time, but none have been adopted to any great
extent. Woolen cloth and lambskin have been used for over
100 years for covering rolls. In fact, the first frame built
§20 DRAWING ROLLS 7
for spinning had top rolls that were covered, the skin being
used without any cloth. The uncovered roll known as the
metallic roll is the only one that has displaced these materials
to any great extent.
8, Roller Clotli. — The cloth that lies underneath the
leather should be made of the finest and best wool. The
wool should be carefully carded, so that every piece of for-
eign matter will be removed, and the weaving and the
finishing of the cloth should also receive very close atten-
tion. It should not be possible to detect by the hand the
slightest variation of thickness in any portion of the cloth.
American and English roll cloths are used in covering rolls.
They vary considerably in weight; the American cloth is
figured on a width of 54 inches, while English cloths are
figured 27 inches in width. It should be remembered, there-
fore, in ordering roll cloth that an American 32-ounce, for
example, is the same as an English 16-ounce.
In mills covering their own rolls, the old leather should be
removed and the cloth carefully examined. If it shows any
evidence of disintegration, or wear, or an uneven surface, it
should be condemned and removed. The old cloth may be
removed by soaking it in water, after which the roll should be
cleaned thoroughly. When rolls are sent out to be covered,
it is considered advisable to cut the cloth with a knife in order
to prevent the same cloth being used again, thus avoiding
the danger of having old cloth covered with new leather.
9. Metliod of Putting on Clotli Covering:. — In cover-
ing rolls, the cloth is cut into strips slightly narrower than
the boss of the roll. A strip of this cloth is then laid fiat on
a table and a clean roll, the boss of which is covered with
glue, is placed on the end of the strip and the cloth wound
on the roll. The roll during this operation should be neither
hot nor cold — simply warm. The cloth is cut with a sharp
knife at the point where it begins to pass around the roll the
second time, and the seam is then pressed into place.
Another method of covering rolls with cloth is to lay a
number of strips of cloth of the required width in a miter box
8 DRAWING ROLLS §20
and cut them to a gauge of the required length, thus giving
15 or 20 pieces of the exact size required to cover one roll.
In this way the cloth ma}' be put on the rolls much faster
than when cutting each piece on the roll. After the cloth is
put on and the seam pressed together with the fingers, the
roll should be put into evening, or smoothing, rolls for the
purpose of smoothing out any lumps or foreign matter that
may have been in the glue, thereby producing a perfectly
true and even surface.
10. Lieatlier Covering for Rolls. — In yarn-prepara-
tion machinery it is the duty of a pair of rolls to maintain a
firm grip on the fibers of cotton as they are passing between
them, and yet the fibers must not be damaged in any degree.
The rolls at the time are revolving in some cases at a high
rate of speed, and therefore the material with which they are
covered should be of such a nature that it will resist a
certain amount of wear. The substance that has been found
most suitable to meet these requirements is the skin of
the lamb or the sheep, or the skin of the goat, which, like
the skins of most animals, consists of more than one layer.
The outside layer is very thin and tough, and, while horny,
is very elastic.
Fig. 4 is a section of sheepskin very much enlarged;
c represents sweat ducts and d the epidermis. This is the
part that withstands the wear when at work. It consists of
a horny layer above the Malpighian nets, or inside layer, and
is commonly called the grain. A fibrous tissue e binds the
true skin / to the epidermis d. This fibrous tissue is formed
of multitudinous fibers bound together by a soft, milky, gela-
tinous substance. Hollow, loose skins result if this sub-
stance is improperly treated during manufacture.
On the character of the fibrous tissue, which is directly
beneath the grain, depends the strength of the skin; the
larger the size of the skin, the coarser and weaker it will be.
The explanation of this is that there are a certain number of
fibers in the tissue at the birth of the lamb that increase in
thickness but do not increase in numbers with the growth of
5 20
DRAWING ROLLS
the animal. The spaces between these fibers are filled in
with a quantity of the gelatinous substance mentioned, much
of which is dissolved in the process of manufacture. There-
fore, as the strength of the skin depends on the number of
fibers, and since in 1 square inch of lambskin there are more
fibers than in 1 square inch of sheepskin, the younger skin
will be the stronger.
Beneath the mass of muscular fibers is the layer / that is
next to the flesh of the animal. This layer is composed of
Fig. 4
cellular matter and varies in thickness in different parts of the
skin. If a roll were therefore covered with a skin of natural
thickness, some rolls or parts of the same roll would vary in
thickness. In order to make the skin the same thickness
throughout, a process known as shaving: is employed.
As skins are usually thicker over the spine from the tail to
the neck, a test can be made after the shaving process to
determine whether they are the same thickness throughout
by making a pile consisting of 50 or 60 skins. If the pile is
10 DRAWING ROLLS ^20
higher in the center than at any other portion, the shaving
process has not been performed properly.
11, The color should also be taken into consideration
when selecting a skin. English skins usually have a color
known as the natural oak-bark color, which is a light brown,
while others are given a reddish color by means of dye.
American skins are usually of a dark-cream color. The red
color is preferred by some spinners, who claim that because
of the color they can more readily see when the cotton is
absent from the rolls, but as the rolls get to be somewhat of
the same color after being used a few days, the red does not
possess an advantage in this respect for any length of time.
The darker the shades, however, the more the grain defects
are hidden from view.
The size and color of skins depend on the size and age of
the animal from which they are obtained. Lambskin is used
for the more delicate work, as it is finer than sheepskin,
while sheepskin (especially that which is old, being thick and
coarse) is used for the coarser work. A top roll is really a
cushion that will only yield enough to prevent crushing the
fibers and yet maintain a pressure against the steel roll. As
the covering for rolls on coarse work must yield to a greater
extent than that of rolls on fine work, it is evident that the
thicker skin and the heavier cloth should be used on rolls for
coarse work.
12. Selection of Skins. — The skin from which the
largest number of roll coverings can be obtained is the most
economical to use, and the number of coverings that can be
obtained from a skin should be estimated when purchasing.
A cot is the piece of leather intended to cover one boss of a
roll, cut to a rectangular shape with two of its edges after-
wards joined together so that the leather will form a tube.
The skin should be purchased by the minimum measurement;
that is, it should be measured at its shortest parts. The
diagram shown in Fig. 5 will serve to illustrate this point.
A parallelogram aaaa, which indicates the area of the
number of leather tubes, or cots, that may be cut, is placed
20
DRAWING ROLLS
11
on the skin and, if the skin is shorter than the distance b b
or narrower than the distance cc, the skin is below the
minimum measurement. The neck should not be measured,
as it is not suitable for roll covering.
The shape of the skin shown in Fig. 5 is the best for roll
skins. If there are any defects, such as knife cuts, or any
evidence of overshaving on the flesh side, the skin is not of
the first quality and can only be used on coarse work.
Fig. 5
Another serious defect is the presence of fine hairs, and if
such are detected the skin should be condemned.
A hard-grained skin, in which the firmness is introduced by
the method of finishing the skin, will not act successfully as
a cushion. The grain side of the skin should feel smooth
and firm, yet be pliable and capable of expansion and com-
pression, while the flesh side should have a nap as fine as
cloth. The effect of handling the whole skin should be the
12 DRAWING ROLLS §20
same as handling a kid glove, allowing for the difference in
substance. The skin when placed under tension and examined
by a magnifying glass should show an unbroken surface with
no cracks on it.
13. Method of Putting on Leatlier Covering.
When placing the leather covering on rolls, the skins are cut
up into strips rather wider than the boss of the roll so as to
allow for burning off the ends. The strips are next cut
into small pieces just sufficient to fold around the boss of
the roll, and their ends are beveled so as to make a joint that
will not be perceptible to the touch. Beveling machines are
used for cutting the bevel, the skin being placed in the
machine so that the knife enters at the flesh side. The
beveled ends are next joined together with cement, great
care being taken in performing this operation. The leather
tube, or cot, is placed in a press for a short time in order to
insure a perfect joint. Hand or power presses are now
constructed in which cots may be made and pressed.
The next operation is to draw the cot over the boss of the
roll — an operation somewhat similar to drawing the finger of
a glove on the finger. The roll is then revolved at a high
rate of speed and any part of the leather that projects over
the boss is burned off by friction with a hard piece of
wood. The charred portion of the skin forms a collar at the
ends of each boss.
With long rolls it is diiScult to make a cot of exactly the
same diameter throughout and draw it on the roll with the
same tension in every part. This difficulty is overcome by
some roll coverers by taking a long strip of leather and
winding it around the roll spirally, attaching it with cement
as they wind it on. The skins in this case are cut into
strips from 1 inch to H inches wide.
The extra cost of covering and the extreme care that is
necessary in order to keep the roll true are the disadvantages
of this method. It is also claimed by some that the cushion
effect of the leather is destroyed by this method of covering,
as a hard piecing extends completely around the roll
§20 DRAWING ROLLS 13
throughout its entire length; while on the roll covered with
a cot, there is one hard piecing straight across.
Among the precautions that should be observed is the
manner in which the roll is placed in the machine. It should
be placed so that it will not run against the joint, and in
some cases the way the lap runs is marked by a dot of ink
on the grain side of the skin. In putting cots on double-
boss rolls care should be taken that the bevels run the same
way and that the cots are of the same thickness.
VARNISHING
14. It is the general practice in almost all mills to varnish
the rolls that perform the heaviest work; namely, the rolls of
the railway head, drawing frame, comber, sliver lap, ribbon
lap, and in some cases the slubber. The reason for this is
that the grain of the leather wears away and becomes broken,
on account of the high speed at which the rolls revolve and
the heavy work that they have to do compared with rolls in
other frames. It is therefore necessary that something
should be used as a substitute for the natural grain of the
leather, which gives the roll its drawing properties, and a
varnished surface has been adopted as the most practical.
Varnished rolls should present a smooth, hard surface that
has dried without cracking and that does not cause fiber or
dust to adhere to it. Too much glue in the varnish gives
the rolls the appearance of a highly polished surface, which
has a tendency to crack when dry, while too little allows
the varnish to wear away very quickly. Almost every mill
has its own system of preparing varnish, while roll coverers
have for sale various compositions for this purpose.
15. Recipes for Roll Varnisli.— Three recipes for pre-
paring varnish are given:
1. 9 ounces of fish glue; 2 quarts of acetic acid; 2 tea-
spoonfuls of oil of Origanum. This mixture should stand for
about 2 days in order that the glue may be thoroughly dis-
solved, after which it may be thickened with fine powdered
paint of any color that may be desired.
14 DRAWING ROLLS §20
2. lo" pounds of fish glue; i pound of gum arable; i pound
of powdered alum; 2 pounds of acetic acid; 4 pounds of water.
This mixture should be thoroughly dissolved over a slow
fire, after which it may be thickened with paint in the same
manner as in the first recipe.
3. 1 ounce of ordinary glue; i ounce of fish glue; i ounce
of gum arable. This mixture should be dissolved in 22 gills
of water and allowed to simmer for 1 hour over a slow fire,
after which 6 ounces of thoroughly ground paint of any color
may be added to thicken it.
In mixing any varnish it should be done in a regular
melting pot In order that It may not be burned. After the
varnish is made it may be kept in stock for any length of
time, but should be put away in a covered receptacle; it is
advisable to have this cover air-tight, although it is not
absolutely necessary. If when it is desired to use the
varnish it is found to be too thick to spread properly on
the rolls, it may be thinned by adding a little vinegar, or
acetic acid; while on the other hand if it is found to be too
thin, a little paint may be added to thicken it.
16. Method of Apjilying the Tarnish. — The methods
of putting the varnish on the rolls differ. One method is to
apply it with a brush the same as in painting a round stick,
taking care to spread the varnish evenly over the surface of
the leather so that when it is dry it will have a true, smooth
surface. Another method is to have a board made a little
longer than the roll and about as wide as the roll is long.
The upper part of the board is covered with woolen cloth,
the cloth being pulled tightly and tacked at the edges. The
varnish is put on the cloth with a brush and the roll moved
over the surface of the cloth by placing the palm of each hand
on the bushing of the roll and moving it backwards and
forwards until the varnish is spread over the whole surface.
In some cases before the roll is varnished it is ground. In
order to insure its being the sam.e diameter throughout its
length. This is a practice that should not be encouraged, as
it shortens the life of the leather.
§20 DRAWING ROLLS 15
The rolls are generally given one coat of varnish, although
sometimes where fine numbers are required they are given
two coats. New, or newly covered, rolls are given two or
even three coats before they are put into the frame, one coat
being allowed to dry before another coat is put on. Care
should be taken that the rolls are perfectly dry before they
are put back into the frame, since if this is not done the
cotton wall stick to them, making it almost impossible to run
the frame. The rolls, if not dry, will also become fluted.
METALLIC ROLLS
17. For many years inventors have endeavored to
substitute something for the common, leather-covered top
rolls, principally because the covering of these rolls is an
item of considerable expense in the production of yarn, and
also because they are troublesome in certain conditions of
the atmosphere or for certain kinds of stock, especially
colored or bleached stock, on account of their licking and
causing bad work. The most practical of the substitutes
that have been tried is to have flutes in the top steel roll
corresponding to those in the bottom roll. The flutes of the
rolls mesh together, but in order to prevent the teeth of one
roll from reaching to the bottom of the spaces between the
teeth of the other roll, the rolls are held somewhat apart
by collars.
There is a wider space between the flutes of metallic rolls
than there is between the flutes of the common bottom steel
rolls, the spacing being the same for both top and bottom
rolls of the same pair. There are, however, different spa-
cings in different pairs of rolls and, as now applied, wider
spacings are used for back than for front rolls.
18. Construction. — A mounted section of a set of
metallic rolls is given in Fig, 6, while Fig. 7 represents a
portion of a pair of these rolls. Fig. 8 is a cross-section of
the same pair, b, b, are the fluted portions of the rolls and
a, a, the collars, which prevent the rolls from coming into
16
DRAWING ROLLS
§20
too close contact. The flutes of the back rolls are always of
a coarser pitch than those of the front rolls, owing to the
greater bulk of cotton that comes under the action of the back
Fig. 6
rolls. The back rolls for drawing frames as now constructed
have 16 flutes on their circumference for each inch of diame-
ter. The third roll has 24 flutes, while the front and second
Fig. 7
have 32 flutes. They are therefore known as rolls with a 16
pitch, 24 pitch, and o2 pitch, respectively.
On a 16-pitch roll the diameter of the collars is .07 inch
§20
DRAWING ROLLS
17
less than the diameter of the fluted section, and as both rolls
are the same, the amount of overlap is .07 inch. With a
24-pitch roll the collars are .06 inch less in diameter than the
fluted section, and on a o2-pitch roll they are .044 inch less.
Thus, the amount of overlap with 24-pitch rolls is .06 inch
and with 32-pitch rolls, .044 inch. This amount of overlap
is sufficient to grip the sliver as shown in Fig. 8.
m„„„„„.,.„„„ ,,,,,,,,/^
Fig. 8
It will be seen that the cotton does not follow a straight
line, as it does with common rolls, but is crimped to some
extent, and if the collar did not keep the rolls partly sepa-
rated, the fibers would be damaged by the contact of the
flutes. The amount of the overlap is so small that it merely
grips the fibers enough to attain a draft and does not dam-
age them to any appreciable extent.
19. Advantage of Metallic Rolls. — The top rolls
of a metallic set are positively driven by the flutes of the
lower roll meshing with the flutes of the upper roll, and
consequently a more positive draft is obtained than with the
18 DRAWING ROLLS §20
common rolls. The cost of roll covering and subsequent
varnishing is saved, and the bad work that arises from imper-
fectly varnished rolls is entirely obviated.
It is claimed that, as metallic rolls run on collars, friction
is greatly reduced; that licking, from the presence of elec-
tricity and atmospheric changes, is prevented; that consequent
waste is avoided; and that the product of each frame equipped
with metallic rolls is greater than a machine equipped with
common rolls running under the same conditions, because of
the curved path taken by the cotton. It is further stated that
metallic rolls produce work that is equal in quality to that
produced by common rolls and that there is no necessity of
keeping extra rolls in stock. However, metallic rolls at the
present time are not used to any large extent except on rail-
way heads, drawing frames, sliver-lap machines, and slubbers.
SETTING AND WEIGHTING ROLLS
ruIjES governing setting
20. One of the most important points in relation to cotton
machinery is the relative position of one pair of rolls to
another, which position is governed by the length of the
staple and bulk of cotton being used. The bad work that
will result from the improper setting of rolls can never be
remedied. In setting rolls, there is one broad principle that
must always be followed: the distance between the centers
of each pair of rolls must always exceed the average length
of the staple of the cotton being used. If this were not so,
the fiber would come under the action of the forward pair of
rolls before it was released by the preceding pair, and since
the speed of the rolls increases with each pair that is nearer
the front of the machine, this would result in the fiber being
strained and broken.
In addition to the length of staple being run, there are
several other principles that should be considered in setting
rolls. Rapidly revolving rolls require wider settings than
§20 DRAWING ROLLS 19
those having slow speed, since with a slow speed the rolls
could be set closer together and still the fibers would be
given a sufficient length of time to be drawn away from the
mass of cotton without being strained. From this statement
the conclusion should not be drawn that, since the front pair
of rolls in any frame revolves faster than the back pair, the
front rolls should be set farther from the middle rolls than the
back rolls; for this is not so, as other circumstances, having
to be considered, overbalance that of the speed of the rolls.
Since the speed of the rolls increases with each pair that is
nearer the front of the machine, the cotton as it passes
through the roll is greatly diminished in weight per yard
from back to front, and since it is much easier to draw the
fibers past each other when there is only a comparatively
small number of fibers than when there is a large number,
two pair of rolls that are near the front would have a less
space between them than two pair of rolls at the back.
For this reason the space between each two pair of rolls in
a set increases from delivery roll to feed-roll. For example,
if the staple of the cotton being used on a drawing frame is
1 inch, the distance between the front and second pairs of
rolls might be li inches; between the second and third,
If inches; and between the third and^ back, H inches.
When the ends put up at the back are heavily twisted, the
settings are wider on the same machine than when the ends
fed are slightly twisted. This is due to the fact that it is
more difficult to draw the fibers past each other in the former
case than in the latter. Harsh, wiry cotton requires wider
settings than smooth, silky cotton, because it does not draw
so easily.
As the rolls are set according to the staple of the cotton
used, it is therefore evident that the rolls intended to run
on coarse counts, which is made from short-staple cotton,
must be smaller in diameter than those intended to work
long-staple cotton, in order that the centers of the rolls may
be brought near enough together. Sometimes the middle
roll is made smaller than the front and back, where three
pair of rolls are used, so that a close setting may be made.
Shorf- 5/-c3p/e
Intermediate
Rov/na frame
2pirtnin^ Frame
Medium SMp/e
Rovini^ Trame
Spinninif rmme
Selfvveighted t>ack
and middle Top rolls i
Lopi^ Staple
Jack Royin^ Frame - Dead Weighted
Self iveiahted l>ack
and m/dal^_Top rolls ,
Jack Roving Frame
Fig. 9
Fig. 10
Fig. 11
20
DRAWING ROLLS
21
The diagrams that are included in Figs. 9, 10, and 11 show
the settings and diameters for different kinds of cotton,
with the method of measuring distances from center to
center of rolls; they will vary, however, according to condi-
tions, as already stated.
The following settings for American cotton of about 1-inch
staple are taken from actual measurements in a mill making an
average of 32s:
TABLE I
^ t^^
Distance Between Centers
0) OS
4, t- O
o
Front
and Second
Second
and Third
Third
and Back
First drawings .
411
68 grains
IT^
nches
li inches
It inches
Second drawings
4ir
68 grains
lA
nches
if inches
if inches
Third drawings .
411
68 grains
if
nches
if inches
if inches
Stubbing ....
I(J2
68 grains
li
nches
if inches
Intermediate . .
M3
.57-hank
II^
nches
if inches
Roving
ii6
i.6i-hank
li
nches
iT% inches
Spinning ....
125
5-hank
111; inches
if inches
Each case of roll setting must be judged by its require-
ments. Table I shows ordinary settings on the inter-
mediates, roving, and spinning, and excessively wide settings
on the drawing and slubber on account of the unusually
heavy sliver and high speed; but in the mill in question,
after numerous experiments were made, it was found that
under the circumstances the best yarn was made with the
above settings. A more ordinary setting for a 60-grain
sliver, 350 revolutions per minute at the drawings, would be
li. If, and 1 2" inches, with the same cotton.
21. Adjustingr Points. — On all the attenuating machines
of a cotton-yarn mill, adjustments are provided by which the
distance between the rolls may be regulated. In Fig. 12, b is
shown as one of the roll stands that support the rolls, this
being a stand for three pair of rolls. The bearing b^ of the
front roll is cast solid with the main support b, and con-
sequently the front-roll bearing cannot be moved. Separate
22
DRAWING ROLLS
20
bearings, which are adjustable, are provided for the other two
lines of rolls; b^ is the bearing for the center line of rolls and
is capable of sliding on b,, while ^3, which is the bearing for
Fig. 12
Fig. 13
the third line, can sHde on b^. Fig. 13 shows a roll stand that
differs somewhat from that shown in Fig. 12, although the
letters of reference will be found to apply to the same parts.
§20
DRAWING ROLLS
23
When it is desired to set the rolls, the set of top rolls that
is at the end of the frame is removed, together with other
sets of top rolls at frequent intervals, usually at every other
stand. The screws b^ that secure the bearings of the bottom
rolls are then loosened throughout the length of the frame.
The required distance between the bites of the rolls should
next be determined, and from this, together with the
diameter of the rolls, the distance between the bosses of
each pair may be learned, after which gauges of the correct
thickness are selected. For example, suppose that the dis-
tance between the centers of the front and second bottom
rolls is to be 1 inch, and the front roll is 1 inch in diameter
^ r^"'
kica
D
[/
and the second roll i inch. Then the space occupied by the
rolls themselves would be the sum of one-half of the diameter
of each roll, which is tV -f A, or if. Since the distance from
center to center is to be 1 inch, the space between the
bosses of the rolls would be 1 — il, or tg inch; therefore, a
-iVinch gauge would be selected in setting these rolls.
These gauges are inserted between the bosses of the rolls,
after which the rolls are drawn up until the gauge sets
snugly, when the binding screws b^ are tightened. This
operation is repeated at every stand where top rolls have
been removed. The gauges used are generally made of
wood, brass, or iron and are about 2 inches long, i inch
wide, and of various thicknesses, in order to suit the work.
22. Cap Bars. — The top rolls have their bearing on the
bottom rolls and are held in position by ap arrangement of
cap bars, one of which is shown in Fig. 14. The cap bars
are constructed in such a manner that the top rolls may be
24 DRAWING ROLLS §20
removed easily, it also being possible to readily turn the cap
bars away from the bottom rolls.
The manner of supporting the cap bars is shown in
Figs. 12, 13, and 14. A shaft e runs lengthwise of the frame
and is supported either by brackets e^. Fig. 12, which are
fixed to the roll stand, or by the bearing of the back roll, as
shown in Fig. 13. On this shaft, at various intervals, are
brackets e.,, Fig. 14, that carry a long finger e^ shaped so as to
fit the hole in the casting e^; on this finger are the nebs e^
that keep the top rolls in position. The nebs are secured
to the finger, and as the holes are made to fit the peculiar
shape of the finger, they are prevented from turning.
23. Setting Top Rolls. — When setting the top rolls, it
is usual to have all the rolls in position and by using the
correct gauges to set these rolls so that they will come
directly over the bottom rolls. In order to move the top
rolls so that they will occupy the correct position, it is
simply necessary to loosen the screws that hold the nebs,
after which the nebs may be moved to any desired position.
In some cases it is the practice to insert the gauges between
the nebs, although this practice is not to be recommended,
since if the nebs are not of the same thickness, the rolls will
not be properly in line.
In connection with Fig. 13 it should be noted that with
the stands constructed in the manner shown in this figure,
the bearings for the back top roll are moved together
with the bearings for the bottom back roll; consequently,
when the bottom back roll is set, the top back roll will
always be in its correct position. This is the more modern,
and is usually considered the better, arrangement.
TOP-ROI.L WEIGHTING
24. In order to maintain a grip on the fibers, the top
rolls must have a constant pressure on the bottom rolls.
The pressure of the top roll on the bottom roll is maintained
by means of weights, light weights being applied to slow-
running frames and heavier ones to frames where the rolls
§20 DRAWING ROLLS 25
run at high speeds, which cause considerable vibration and
tend to jerk the top rolls. The system of weighting is
classed as follows: (1) Self-iveighting; (2) dead-weighting,
which may be subdivided into {a) direct dead- weighting and
{b) weighting with the intervention of springs; (3) lever-
weighting, which may again be subdivided into {a) direct
weighting and {b) weighting by saddles and bridles.
SELF-WEIGHTING
25. The method known as self-weighting consists of
having the top roll heavy enough to maintain the necessary
pressure on the fiber, and is used on the center and back
rolls of fine roving frames, spinning frames, and mules
intended for very fine spinning. The middle roll, which is
usually \ inch in diameter, weighs from 2 to 4 ounces, while
the back roll, which is from 2 to 2i inches in diameter,
weighs from \\ to 2i pounds. This method is shown in
Fig. 11, where the back and middle rolls of one of the jack-
frames, the mule, and the spinning frame are self-weighted.
Since in spinning fine numbers the rolls generally have a
slow speed, this amount of weighting is sufficient to give the
necessary grip on the fibers. The method of self-weighting,
however, cannot be applied to all classes of work, since,
where the work is coarse and the top rolls require consider-
able weight, if they were made large enough to give this
weight, they would be too bulky for use. On coarse work
the rolls revolve rapidly and the vibration caused would
prevent satisfactory use of self-weighting systems.
DEA1>-^VEIGIIT1NG
26. The method known as dead-weigliting is shown in
Fig. 15. The rolls a, b illustrate direct dead-weighting, one
weight serving for one roll; but by using a saddle d., and
bridle ^3, as shown in Fig. 16, one weight can be used for
two rolls, which reduces the number of weights on a machine.
The system of dead-weighting in which a spring inter-
venes between the weight hook and weight is shown on the
26
DRAWING ROLLS
§20
rolls c, d. Fig. 15. The object of adopting this construction
is to have the spring tend to neutralize the effect of any
slight shock that the roll may receive
6.
Fig. 15
If, in the case of Fig. 15, the rolls are single-boss rolls»
then there will be a weight similar to w suspended from
each end of each top roll; consequently, if the weight is»
§20
DRAWING ROLLS
27
say, 14 pounds, each top roll will exert a pressure of
28 pounds on the bottom roll. If the top rolls are double-boss
Fig. 16
rolls, there will be one weight suspended from the center of
the roll, each boss having a bearing point on the bottom
28
DRAWING ROLLS
20
roll, and if the weight zv weighs, say, 20 pounds, each boss
will exert a pressure of 10 pounds on the bottom roll.
In the case of Fig. 16, the weight w will be distributed
somewhat differently. If the top rolls are single-boss rolls,
there will be weights similar to 7v at each end of the roll, and
if these weights weigh, say, 20 pounds, there will be a pres-
sure of 10 pounds on the end of each top roll, giving a total
Fig. 17
pressure of 20 pounds on each roll. If the top rolls are
double-boss rolls and the weight is, say, 30 pounds, then there
will be a pressure at the center of each roll of 15 pounds, caus-
ing each boss of one top roll to exert a pressure of 7i pounds
on the bottom roll.
LEVER-WEIGHTING
27. The principle of lever-^v^eigliting is that of
exerting pressure by means of a weight acting through
a lever. By this means a smaller weight may be used and
§20
DRAWING ROLLS
29
the same pressure obtained as when a larger weight is
employed in the sj-stem of dead-weighting. The pressure
can also be very readily varied by moving the weight on
the lever.
A method of lever-weighting is shown in Fig. 17. A sad-
dle d^ has a bearing at its forward part on the top front roll,
and also another bearing on the smaller saddle at g. The
small saddle has bearings on the back and center rolls.
Suspended from d. is a rod d^ linked to a rod j. This rod
passes through a hole in the roll beam and supports the
lever //, which is fulcrumed
under the roll beam at /. The
lever // carries the weight u\
the position of which may be
varied and thus different pres-
sures obtained on the rolls, as is
desired. The method of obtain-
ing the amount of pressure
exerted at any point by lever-
weighting is somewhat more
complicated than in the case of
dead-weighting, and in order to make this somewhat clearer,
reference is made to Fig. 18, together with the following
data: The weight of w is 4 pounds; the distance of iv f is
Ti inches; p{,\ inch; j k, f inch; /: /, If inches; /w, \ inch;
myi, \\ inches; /;/, 1 inch; j I, 2 inches. The total pressure
will equal
Weight X Ti!' / _ 4 X 7i
Fig. 18
P{
40 pounds, total weight on all rolls.
Part of this 40 pounds will be distributed on j and the
remainder on the point g.
The pressure on j will equal
/^/X 40 ^ 11 X 40
jl 2
= 271 pounds
The pressure at g equals 40 — 272 = 12i pounds, or the
pressure at g will equal
y/feX40 ^ f X40
jl 2
= \1\ pounds
30
DRAWING ROLLS
§20
The pressure at n will equal
/ m X 12i i X 12i
= 4.166 pounds
m n li
The pressure at m will equal 12^ — 4.166 = 8.33 pounds, or
the pressure at m will equal
/^Xm IX 12i „^_ ,
= — TT — = 8.33 pounds
m n \^
28. In Fig. 19, a system sometimes used for weighting
the rolls of a spinning frame is shown. This method differs
but slightly from that shown in Figs. 17 and 18. The
Fig. 19
weight w is supported by the lever //, which at the point / is
inserted in a hook fastened to the roll beam. Connected to
the lever h is a hook d^, that is supported by the saddle d^,
which has a bearing on the front top roll and on the saddle g.
The saddle^ has a bearing on the back and middle top rolls.
29. Metallic rolls do not require so much weight as com-
mon rolls; usually a weight of about 14 pounds is used on
each end of the four rolls of a drawing frame, although this
sometimes differs and a weight of 10 pounds is used for the
front, 12 for the second, 14 for the third, and 16 for the
fourth. In experimental cases, metallic rolls have been run
§20 DRAWING ROLLS 31
with as low a weight as 6 pounds. Some prefer to have the
heaviest weight on the front roll, claiming that as this roll
revolves at the highest speed it therefore requires more
weight to keep it steady. The following list of weights,
which was taken from machines running medium counts,
will give a general idea of the relative weights on the rolls
in different machines, but it should be understood that the
weights given here will serve simply as a guide, since the
weights that are used are largely dependent on the ideas of
the builder, the ideas of the purchaser, the construction of
the machine, and the class of work to be run.
On the drawing frames using single-boss metallic rolls
there was a weight of 18 pounds on each end of the front
rolls, giving a total of 36 pounds pressure on the front roll.
The second roll carried 16-pound weights, giving a total of
32 pounds. The third and back rolls carried 14-pound
weights, giving a pressure of 28 pounds on each roll. All
of these were dead-weighted.
On the drawing frames using single-boss common rolls the
front rolls carried 22-pound weights at each end, the second
rolls 20-pound weights, the third rolls 18-pound weights, and
the back rolls 16-pound weights, giving a total weight of
44, 40, 36, and 32 pounds on the front, second, third, and
back rolls, respectively.
On the slubbers using double-boss common rolls the front
rolls were dead-weighted and carried a weight of 12 pounds,
thus giving a pressure of 6 pounds on each boss. The
middle and back rolls supported a saddle from the center of
which was suspended a 12-pound weight, giving a pressure
of 3 pounds on each boss of both middle and back rolls.
On the first intermediates using double-boss common rolls
the front rolls were dead-weighted and carried a weight of
16 pounds, giving a pressure of 8 pounds on each boss of the
roll. The middle and back rolls carried a saddle from which
was suspended an 18-pound weight, thus giving a pressure
of 4i pounds on each boss of both rolls.
The second intermediates using double-boss common rolls
were dead-weighted throughout and carried weights of 18,
32 DRAWING ROLLS §20
14, and 12 pounds on the front, middle, and back rolls,
respectively, thus giving a pressure of 9 pounds on each boss
of the front rolls, 7 pounds on each boss of the middle rolls,
and 6 pounds on each boss of the back rolls.
On the roving frames the front rolls were common double-
boss rolls, being dead-weighted, and carrying a weight of
8 pounds, thus giving a pressure of 4 pounds on each boss.
The middle and back rolls were self-weighted.
weight-reijIeving motions
30. It is necessary to use every precaution to keep a
leather-covered roll as perfectly round and smooth as
possible, in order to insure good work; and, for this reason,
weiglit-relieving motions are applied so that there will
not be any pressure on the rolls when they are to stand idle
for any considerable length of time. If the pressure were
maintained on the rolls during the time that they were
stopped, a depression would be formed at the point where
the steel roll was in contact with the leather of the top roll,
because of the yielding properties of the leather, and when
the machine was again started there would be a slightly
eccentric running of the roll, which would produce irregu-
larity in the work.
In some cases where there is not a weight-relieving
motion, it is necessary to remove the hooks from each
weight by hand. An arrangement that makes this operation
easier and more simple is shown in Fig. 15. The weights w
are suspended from the rolls, as shown, each weight having
a hole in it through which an eccentric ^ passes. By turning
the handle s^ until that part of the eccentric which is farthest
from the center of the shaft that supports it is at the top,
the weights will rest on the eccentric, and thus the pressure
on the rolls is relieved. With this method an eccentric must
be provided for each set of weights.
An arrangement by which two eccentrics serve for a
number of sets of weights is shown in Fig. 16, and consists
of bars e, d that run lengthwise of the machine and pass
^20
DRAWING ROLLS
33
through holes ih the hooks /, /, supporting the weights w.
These bars have a bearing at each end on an eccentric 5 and
thus, by turning the eccentric by means of the handle s,, the
bars, and consequently all of the weights supported by the
hooks through which the bars pass, are raised.
CLEARERS AND TRAVERSE MOTIONS
CLEARERS
31. In order to prevent the accumulation of dirt and
fibers on the rolls, what are known as eleai-crs are utilized.
The construction of a clearer used on railway heads, drawing
A:,
Fig. 20
frames, and fly frames is shown in Fig. 20. It consists of a
piece of flannel a supported from a piece of wood /; by
means of rods r, and spikes c; b is held in position by means
of screws, similar to h, which pass through a slot in a
34 DRAWING ROLLS § 2C5
bracket £- attached to the roll cover k. By this means the
wood b may have a vertical movement. As the flannel is
pressed against the rolls by the weight of the wood, the
rolls are effectively cleaned. If clearers of this type are not
cleaned as often as necessary, the clearer waste will gather
at the points <?,, e. and eventually drop into the cotton that is
passing through, causing bad work at the next process.
When cleaning by hand, it is necessary to lift the cover,
which is hinged at /, and remove the waste; to obviate this
operation, self-cleaning clearers are sometimes attached.
There are several styles of self-cleaning clearers; one that
is being used to a very large extent consists of an endless
apron of very heavy cloth that passes around two rolls, one
of these rolls being situated above the back roll of the frame,
while the other is situated over the front roll. The back
roll of this clearer motion is driven by gearing and has a
very rough surface, thus causing the cloth to revolve, while
the front roll is driven by the friction of the cloth passing
round it. These rolls are so placed that the cloth will press on
the top rolls of the frame, thus cleaning them while the cloth
itself is cleaned mechanically by a comb.
Another type of clearer is shown beneath the rolls in
Fig. 20. This type may be applied underneath at the spaces
between any two lines of rolls, as it is on drawing frames.
On fly frames, however, it is usually put between the first
and second rolls only. It consists of a piece of wood / as
long as the box of each frame. Two faces of the clearer are
curved in such a manner that they correspond with the
curvature of the rolls. This clearer is covered with flannel
and is held in position by two pieces of lacing, one at each
end, similar to w. These lacings pass over the front roll
of the two with which the clearer is in contact, and
have weights n at their ends. By this means the clearer
maintains a pressure on the rolls and consequently cleans
them.
Another style of clearer used underneath the rolls has a
wooden roll covered with coarse woolen cloth, and is held
against the bottom roll by springs. This clearer is revolved
§20
DRAWING ROLLS
35
by frictional contact with the roll, and thus, whenever an end
breaks, the clearer winds the cotton on itself and prevents
its getting on the steel roll. This type of clearer is applied
underneath the front roll.
TRA AVERSE MOTIONS
32. Traverse motions in one form or another are used
in connection with leather-covered drawing rolls, and have
for their objects economy in roll leather and better quality of
product. If the strand of cotton were permitted to pass
between the leather roll and steel roll at one point continually,
a groove would form around the rolls, and consequently they
would soon lose their grip on the fibers. To prevent this, a
motion is applied xvhereby the sliver, or roving, is given a
traversing motion along the boss of the roll. In its simplest
form the motion usually consists of a traverse bar /, Fig. 21,
mg^
that carries guides or is drilled with small holes t^ through
which the strand of cotton is passed before entering the back
rolls. Attached to the traverse bar is a connecting-rod e that
is connected to the crank-stud c,. The crank-stud is con-
nected to a casting /, which is connected to the worm-gear c
by the stud A and nut /., thus causing r, to be eccentric with
reference to c. The worm-gear is on a short shaft and is
driven by the worm r, on the back roll. As the back roll
revolves it gives a traversing motion to the traverse bar /
by means of the worm-drive and crank-arrangement.
36
DRAWING ROLLS
§20
Most traverse motions are supplied with some means of
lengthening- or shortening the length of the traverse. With
the construction shown in Fig. 21 it is possible, by loosening
the nut /. and swinging the casting / on the stud A, to bring
e^ nearer to or farther away from the center of the gear c,
thus decreasing or increasing, respectively, the length of the
traverse.
In some cases the traverse bar has attached to it a lever
carrying a stud that is kept in contact with a heart-shaped
cam by means of a spring. The cam receives motion in the
same manner as the crank described, and as it revolves it
forces the lever in one direction during a part of its revolu-
tion, while the spring serves to draw the lever in the opposite
Fig. 22
direction during the remainder of the cam's revolution. The
crank-arrangement is more positive than the cam and spring,
but at the points of change, or where the crank-stud <?i is at
its dead centers, the motion of the traverse guide is slower
than at any other part of the traverse, thus causing the
strand of cotton to produce a greater amount of wear at these
places. The extent of the traverse given with a cam- or
crank-motion is shown in Fig. 22 (a).
The main principle of construction that has been sought in
traverse motions is to have a variable traverse; that is, to
have different lengths of sweep so that the traverse will not
be continually changing at the same point on the circum-
ference of the roll. An arrangement that gives a variable
20
DRAWING ROLLS
37
traverse similar to that shown in Fig-. 22 {b) is shown in
Fig. 23, in which {a) is a front view and (^) an end view,
partly in section.
The back roll t^ carries a worm 4 driving two worm-gears
c, c, that vary slightly in the number of teeth. Forming a
part of the worm-gear c^ is an eccentric d^, while the eccentric
4, ,t.
d is, di part of the worm-gear c. The
worm-gears c,Cy are mounted on a
stud c, that is supported by a bracket
attached to the roll beam. Connected
to the eccentric ^ is a lever / that is
attached at its other end to a stud h^
connected to the lower end of the
bracket g. The eccentric d^ also car-
ries a lever e, which is connected to
a stud h that is also carried by the
bracket^. The bracket^ is connected
by means of the stud g, to the trav-
erse bar /. As the worm-gears <r, c^
have different numbers of teeth and
are driven by the same worm, the two eccentrics that form
part of these two worm-gears will have their relative posi-
tions changed; thus, at one time the eccentrics may coincide,
in which case the levers e, / will be moving the bracket g in
the same direction and the traverse rod t will be receiving
its shortest traverse. At another time the highest parts of
38
DRAWING ROLLS
§20
the eccentrics d, d, will be brought diametrically opposite
each other, in which case the lever e will be moving in one
direction as far as possible, while / will be moving in the
other, resulting in the traverse guide receiving its maximum
traverse.
9
The slot g^ in the bracket g allows this bracket to be
raised or lowered, thus shortening or lengthening the
extreme length of the traverse, as may be desired. When
the traverse guides t^ are at the center of the boss of the rolls,
Fig. 25
the bracket g should be exactly perpendicular, and in order to
accomplish the settings of the different parts, slots are pro-
vided in the bracket^ at the points where the studs //, h^ are
situated, thus allowing the bracket to be placed in its correct
position.
§20 DRAWING ROLLS 39
33. Doiible-Bai" Traverse Motion. — With the traverse
motions just described, it will be observed that as the cotton
is passing through the guides /., Fig. 24, the strand nearest
the neck^, or where the weight is applied, is under a greater
pressure than the strand under the opposite boss, owing to
the distance from the weight. It will be seen then that there
is only one point in the traverse where the weight is equally
divided between the two strands; viz., the center.
To overcome this, a motion known as the double-bar
traverse motion, Fig. 25, has been introduced. With this
motion the strands under each boss are operated by separate
bars rt, «!, which move all the strands of cotton toward the
necks of the rolls at the same time, thus maintaining an
equal distance between all the strands and the necks of the
rolls and causing the weight to be equally divided at every
point of the traverse.
SCOURING ROLLS
34. The cleanliness of the fluted rolls, as well as the
leather-covered rolls, is an important question, since if the
dirt and other foreign matter that collects in the flutes and
bearings of the rolls is not removed, considerable waste and
consequent loss of production and bad work will result from
the cotton adhering to and winding around the rolls instead
of being delivered at the front of the machine. The cotton
collecting in the bearings of the rolls will also cause the
rolls to bind, and thus wear out the bearings and cause con-
siderable strain on the gearing that drives the rolls.
The rolls should be removed periodically from the dif-
ferent machines in order to properly clean the bearings,
necks, and fluted parts, which operation is known as
scouring. The time for scouring depends largely on the
amount of work and the kind and speed of the machine, as
well as on other circumstances. The rolls in machines
used for carded work should be scoured oftener than those
used for combed work, and those for coarse work oftener
than those for fine work. The rolls of the drawing frame
should be scoured about once a month, while those of the
40 DRAWING ROLLS §20
roving frame require scouring: only about every 6 months.
The times of cleaning the rolls of the frames intervening
between the drawing frame and roving frame should be in
proportion to the amount and quality of the work that they
are producing.
When the bottom rolls are removed for scouring great
care should be taken, especially when the rolls are very long,
that they do not become bent or strained, since if they are
replaced in the machine in this condition they are liable to
bind in the stands and produce cut work. In removing the
rolls two or three persons are usually employed in lifting
them from their bearings and placing them on stands,
horses, or brackets suitable for the purpose.
After the rolls have been removed they should be rubbed
with a piece of card fillet in order to remove any dirt, hard
oil, or other substances that may collect in the flutes. After
cleaning the roll in this manner it should be covered with a
paste made of oil and whiting and thoroughly scoured by
rubbing with another piece of card fillet, care being taken
not to rub around the circumference of the roll but length-
wise, so that the wires of the card fillet will follow the
grooves of the flutes and clean them.
After this the roll should be wiped with a piece of dry
waste, covered with dry whiting, in order to thoroughly dry
the flutes before the rolls are replaced. In some cases
dry whiting is used in place of the paste. Care should be
taken not to allow any of the whiting to collect in the
flutes or bearings of the roll.
After the rolls have been scoured they should be examined
in order to ascertain if there are any rough places; and if
such are found they should be smoothed by using a piece of
pumice stone, a piece of very fine emery cloth, or a fine
fluted file. In most cases the pumice stone or emery cloth
will be found sufficient, and the file should not be used unless
absolutely necessary.
The stands or bearings of the machine should be thor-
oughly cleaned with a piece of dry waste and examined to
ascertain if there are any bearings that are badly worn; if
§20 DRAWING ROLLS 41
there are, they should be replaced, care being taken that the
new ones do not stand higher than the others. If any loose
joints are found in the roll, the portion containing the same
should be removed from the remainder and taken to the
machine shop to be repaired. The same care should be used
in replacing the rolls that was taken in removing them.
It is advisable after the rolls have been replaced to place
a small portion of grease on the necks of all the rolls before
the top ones are replaced. This insures a perfect lubrication
of the bearings and lasts longer than oil; it also avoids the
necessity of frequent oiling, although the rolls should be
oiled at least once a week.
If leather-covered top rolls are used in a machine these
should be thoroughly cleaned and revarnished and the
bearings oiled before being replaced, while if metallic top
rolls are used they should be cleaned in a manner similar
to the bottom rolls.
RAILWAY HEADS AND
DRAWING FRAMES
RAILWAY HEADS
INTRODUCTION
1. A machine in use in some of the older cotton mills of
the country but fast passing into disuse is that known as the
railway lieatl. At one time it was the custom to arrange
stationary flat cards in sections of from six to twelve, and
instead of having a coiler at each card, as is now customary
with the revolving fiat card, a long trough was placed in
front of each section of cards, so that the sliver was
deposited on an apron in the trough, or railway, and car-
ried to the head end of the section. At this head end, or
delivery end, was placed a machine, called a railway head,
from its position at the head of the railway, into which the
slivers from the cards were drawn and combined into one
sliver. This must not be confused with a somewhat similar
arrangement in mills making double-carded yarns, by which
the slivers from one section of cards are combined into a
lap or portion of a lap to be recarded. Both of these
arrangements are now passing out of use, the most popu-
lar and most satisfactory method of preparing carded yarns
being to use the revolving flat card, at which the sliver is
deposited in a can by means of a coiler; the full can is then
carried directly to the back of the first drawing frame. In
some cases, the sliver is taken from the card to the back of
For notice of copyright, see page immediately following the title page
2 21
2 , RAILWAY HEADS §21
a railway head of modern construction, which takes the
place of the first drawing frame.
The older style of railway heads, which are combined
with a section of cards, will be only briefly described; but
a full description will be given of those that are used
entirely separate from the cards. In the older type, when
the cotton sliver leaves each card it is delivered into a
trough on to an endless apron, about 12 inches wide, that
consists of canvas covered with a layer of rubber. At
intervals along the trough are sets of wooden rolls, the
upper ones resting on the cotton and condensing the slivers,
while the lower ones support the apron; both the top and
bottom rolls are driven by friction. After passing the point
where the last card delivers its sliver into the trough, all
the slivers pass between two solid steel rolls, which con-
dense the slivers into a still more compact mass; these rolls
are positively driven and the lower roll drives the apron.
The assembled slivers, after leaving the apron, form a com-
pressed sheet of cotton, thicker in the center than at the
edges, and pass to the back roll of the railway head. The
slivers are delivered into the trough in such a manner that
more will lie in the center of the apron than at the edges.
Thus, the whole of the cotton is more liable to remain on
the apron than if it were as thickly distributed at the edges
as in the center.
It is obvious that coilers and cans are not needed at each
card, the product from a whole section of six, eight, ten, or
twelve cards being delivered to one railway head, which
deposits it in a can about 20 inches in diameter. In prin-
ciple this type of railway head differs in no way from those
used at the present time, and in construction resembles that
described in Art. 10 and illustrated in Figs. 7, 8, and 9.
2. Objects. — The objects of the railway head are as
follows: (1) To even the sliver as far as possible; (2) to
parallelize the fibers of the sliver. The methods by w^hich
these objects are attained are: (1) doubling, or combining
several slivers into one; (2) using an evener attachment;
§21 AND DRAWING FRAMES 3
(3) drafting, which causes the fibers to lie more nearly
parallel.
It will be noticed that no mention is made of any cleaning
action; in fact, in the ordinary layout of cotton mills the
cleaning of the fiber from impurities ends with the card.
This is not always true, however, because in mills making
very fine or high-grade yarn a cleaning process, known as
covibing, is introduced, but this is seldom used in mills making
any other class of yarn. It may be accepted as generally true
that any machine subsequent to carding is not intended as a
cleaning machine.
PRINCIPAI. PARTS OF THE RAILWAY HEAD
3. Front and back views of a railway head that takes the
sliver from the cans filled at the card are shown in Figs. 1
and 2, respectively, while Fig. 3 shows a plan view of the
same machine with covers and certain parts removed. The
usual number of cans placed at the back of this machine
is eight, although it is also constructed for other numbers.
Referring to Figs. 1, 2, and 3, the slivers from the cans at the
back of the machine pass through the guides a, over the
spoons b, there being one spoon to each sliver, and then to
the back rolls c. The slivers are then subjected to the drafting
action of four sets of rolls, and passing from the front rolls r,
are combined into one sliver at the trumpet d, from which
they pass to the calender rolls c, c^, through a coiler, and
into a can, the coiler and can arrangement being very similar
to that found at the card.
Railway heads are built in two styles, single and double.
Fig, 1 illustrating what is known as a single railway head.
Double railway heads are constructed much the same as
single railway heads, the principal difference being that in
the former case two machines are combined into a single
machine having two heads and, consequently, two deliveries.
By this means a slight saving in floor space is effected, by
slightly reducing the length as compared with two single
heads, and also by reducing the number of passages among
the machines; there is also a slight economy of power.
RAILWAY HEADS
§21
Fig. 1
21
AND DRAWING FRAMES
Fig. 2
6
RAILWAY HEADS
§21
Stop-motions are provided on railway heads to stop the
machine when a sliver breaks or runs out at the back, when
the sliver breaks at the front, and when the can at the front
becomes too full. Since all these motions are similar to
Fig. 3
those serving the same purpose on the drawing frame, which
will be fully described later, a description of them is not
given here. One motion, however, that is found on the
railway head but is not applied to drawing frames, namely,
the evener motion, is given a complete description.
§21 AND DRAWING FRAMES
EVENER MOTION
4. The object of the evener motion of a railway head
is to so regulate the draft of the machine by means of cones
that, in case the total weight of the slivers fed in a given
time varies, the weight per yard of the sliver delivered
remains the same. These cones may be placed either under
the machine or at the side, the latter method being adopted
in the machine illustrated in Figs. 1, 2, and 3, where the cones
are shown at e^,e^. Referring to Fig. 1, the pulley /, on the
shaft / is driven from the main shaft or countershaft of the
room. On the shaft /is another pulley Z^, which drives the tight
and loose pulleys Z^, /,. Both the tight pulley and the cone ^,
are fast on the end of the front roll f,, so that the speed of
these parts is the same and constant. The cone ^,, by means
of a friction belt e, drives the cone c. This friction belt
simply forms a ring that passes loosely around the cone e^,
and is capable of being shifted from one position to another
by means of a belt guide. These parts are more clearly
shown in Fig. 3. Fast to the shaft with the cone e. is the
gear £', Figs. 2 and 3, that drives the back rolls c by means
of suitable gearing. The back roll drives the third roll;
consequently, the draft between these two rolls is always con-
stant, provided that the gears on the ends of these rolls are
not changed. This is also true of the front and second rolls,
since the second roll is driven from the front. Thus the
break draft in this case is between the second and third rolls,
so that if the back and third rolls are speeded faster or slower,
the break draft and, consequently, the total draft of the
machine will be changed. Thus it will be seen that the
position of the friction belt between the two cones regulates
the draft of the machine. For example, if the friction belt
is between the large end of the driving cone e, and the small
end of the driven cone c, then the cone e^ will be driven at
its maximum speed, which in turn will drive the back rolls at
their highest speed, thus increasing the feed and diminishing
the draft of the machine, since the speed of the front rolls
remains the same. On the other hand, if the friction belt is
RAILWAY HEADS
21
shifted to the small end of the driving cone and the large end
of the driven cone, then the cone e^ will be driven at its
lowest speed, which in turn will drive the back roll at
its lowest speed, decreasing the amount of stock fed in and
increasing the draft. This is the method adopted on railway
heads to regulate the weight of the sliver delivered; that is, if
the weight fed is too heavy, the draft is increased, whereas
if the weight fed is too light, the draft is diminished.
5. In all railway heads, the principle adopted to control
the movement-of the belt on the cones consists of passing the
Fig. 4
sliver through a trumpet-shaped guide attached to one end
of a lever that is pivoted near its center and carries at its
other end an adjustable weight. This weight is so placed
on the lever that it exactly balances the downward pull of
the sliver when the correct weight is passing through the
trumpet; consequently, if the sliver is too light, the trumpet
rises, while, on the other hand, if the sliver is too heavy, the
trumpet is depressed, the belt in either case being moved to
the correct position on the cones to restore the sliver to its
correct weight.
§21
AND DRAWING FRAMES
In describing the method of regulating the position of
the friction belt between the cones, reference is made to
Fig. 4, which shows a front view, and Fig. 5, which shows a
side view, partly in section, of the parts of this motion; as
most of these parts are also shown in Fig. 3 and are lettered
the same in each figure, reference should be made to all three
figures. The trumpet d is situated on a long lever d^ pivoted
at d^ and connected at its rear end to a rod //, which in turn is
connected to a rod h, running diagonally across the machine
Fig. 5
from back to front, as shown by the dotted lines in Fig. 3.
Connected to the rod //, at the front of the machine is a vertical
rod h,, which is connected to a shield j that nearly covers a
gear /,. The top part of this shield is cut away in order to
expose the teeth of the gear /, for a short distance. The
weighty, simply serves to steady the shield. Worked by an
eccentric -^ is a rod k^ that extends across the front of the
machine and is connected at its other end to an upright rod X',,
which imparts a horizontal oscillating motion to the pawls r, ; ,.
10 RAILWAY HEADS §21
On the shaft with the gear /, is a gear ^ that meshes with the
teeth of a rack Si, which carries the belt guide s^ that governs
the position of the friction belt e.
The action of this mechanism is as follows. The weight da
is so placed on the lever d^ that when the correct weight of
cotton is passing through the trumpet d, the pawls r, r, rest
on the outside of the shield j and the friction belt is at the
center of the cones. If, however, the cotton passing through
the trumpet is too heavy, the trumpet is pressed down, which
action will raise the back end of the lever d^, causing the rod /i
to be lifted. The rod /i in being lifted brings with it the back
end of the rod //,, thus causing its forward end to be lowered,
which in turn lowers the rod //,, turns the shield to the left,
and exposes the gear j\ to the action of the pawl r. As the
gear j\ is turned, the gear s is turned, moving the rack and
the belt guide in such a direction as to shift the friction belt
toward the large end of the driven cone, thus causing less
cotton to be fed in and decreasing the weight of the sliver
delivered at the front. This allows the weight to bring the
trumpet and the parts connected with it to their normal posi-
tions, causing the shield to again prevent the pawls from
acting on the gear/i. In case the sliver passing through the
trumpet at the front of the machine is too light, the action of
the different parts will, of course, be the exact reverse of that
described. It is possible to so alter the throw of the eccen-
tric k that the action of the pawls will give a change as small
as 2 grain to the yard for each motion of the pawls, or as
great as li grains to the yard.
6. The chief criticism that can be made on a railway head
is that it does not act on the stock passing through it until at
least a part of the faulty stock it is supposed to correct has
passed beyond the action of the evener motion. For example,
the evener motion illustrated here is actuated by the trumpet,
which is at the front of the machine, while it regulates
heavy or light work by changing the speed of the back
rolls; consequently, any sliver that is heavy or light enough
to cause the trumpet to change its position will have already
§21 AND DRAWING FRAMES 11
passed into the can before the draft of the machine is
changed, and the weight of that part of the sHver at least
will not be remedied. On some railway heads, the draft of the
machine is changed by the evener motion altering the speed
of the front rolls, but the same criticism still holds good.
The evener motion of a railway head is the most difficult
part of the machine to keep in good running condition, and
care should be taken that all of its parts are always clean
and that all the moving parts are well oiled and carefully
adjusted. There should be no backlash or slippage in any
parts that will prevent the friction belt from being immedi-
ately moved when too heavy or too light a sliver is passing
through the trumpet. The trumpet should be carefully regu-
lated so that it will be in the correct position when the
desired weight of sliver is passing through, and after it has
once been balanced, care should be taken to keep it in its
correct position.
In extreme cases in the North, there is a slight contrac-
tion in the trumpet during the night in winter, which affects
the sliver slightly when first starting up in the morning,
causing it to be a little lighter than the night before. This
trouble is not experienced in the South, as the temperature
is more even.
7. The draft of a railway head generally slightly exceeds
the doublings. The gearing of the machine that has been
illustrated is shown in Fig. 6, and the draft between the
back roll and calender roll would be as follows with leather-
covered top rolls, supposing the belt to be at the center of
the cones:
2 X 32 X 24 X 100 X 60
24 X 45 X 24 X 30 X If
= 8.619, draft
8. The floor space occupied by a single railway head,
such as has been illustrated, is 3 feet 32 inches by 5 feet
3 inches, while a double railway head occupies 6 feet
41 inches by 5 feet 3 inches. These dimensions allow for
the space occupied by the cans placed at the back of the
machine. The type of railway head illustrated weighs,
12
RAILWAY HEADS
§21
Fig 6
§21
AND DRAWING FRAMES
13
941
approximately, 1,200 pounds per delivery, while about
1 horsepower is required to drive three deliveries.
9. The speed of the front roll of a railway head may be
from 300 to 500 revolutions per minute for a It-inch roll.
The production at
400 revolutions with
a 50-grain sliver, ma-
king an allowance of
20 per cent, for stop-
pages, is about 165
pounds in a day of
10 hours; with a 60-
grain sliver, about
200 pounds; and with
a 70-grain sliver,
about 285 pounds.
10. Another type
of evener motion, and
one that is more com-
monly found on rail-
way heads, has the
cones situated under
the roll beam. These
cones, which are con-
siderably larger than
those in the railway
head previously de-
scribed, are about 13
inches long, 7\ inches
in diameter at the
large end and 5 inches
at the small end,
although they vary in
different makes. Fig. 7 shows the gearing of the machine
under description. The driving pulley is on the shaft with
the top cone, while on the other end of this shaft is a gear
that drives the front roll by means of carriers; consequently,
OiangeGear
%-
Fig.
14
RAILWAY HEADS
§21
the front roll is always driven at a constant speed. On the
end of the bottom-cone shaft is a bevel gear driving another
bevel on an upright shaft that drives the back roll. The
third and second rolls are driven from the back roll.
The calender rolls and coiler are driven from the front
roll, while the cone belt is required to drive the second, third,
and back rolls. Since these rolls are driven through the
cones, their speed will depend on the position of the cone
belt on the cones and, as in this motion the amount of fric-
tion on the trumpet determines the position of the belt on
Fig. 8
the cones, the second, third, and back rolls are driven at
varying speeds, in order to regulate the weight of the sliver
delivered.
Fig. 8 shows a side view of the trumpet and its connec-
tions, while Fig. 9 shows two views of the cones and their
connections, (a) being aback view and (d), a side view. The
cone belt a, Fig. 9 (a), is moved along the cones b,b,
by means of a shipper fork c that is cast with a hub <:,,
which contains a coarse thread to engage with the thread
of the shipper, or evener, screw c^. Any motion given to
this screw will therefore alter the position of the cone belt
§21
AND DRAWING FRAMES
15
on the cones. The evener screw has a bearing, or support,
in brackets attached to the framework and carries at one end
a small gear r,, Fig. 9 (a) and (d), that is driven by a gear d
operated by the pawls e,e,, which are mounted on the arm e,
of a casting e.. that is pivoted at e,. Another arm e. is con-
nected by means of a crank-motion to the gear /, which is
Fig. 9
driven from the gear ^ on the bottom-cone shaft. As the
gear / revolves it causes the crank-motion to impart an
oscillating motion to the bracket, or casting, e„ thus causing
the pawls to rock back and forth. When the weight of the
sliver is running even, the pawls are kept out of contact with
the gear d by means of the guard plate d^.
16 RAILWAY HEADS §21
Referring- to Fig. 8, the bracket //,, that is attached to the roll
beam, supports the trumpet /?, which is pivoted at the point h^.
Thus the amount of friction caused by the sliver passing
through the trumpet is allowed to regulate the relative posi-
tion of the trumpet with regard to the calender rolls /, /,.
When the trumpet is drawn forwards by the friction of the
sliver, the lug h^ on the trumpet comes in contact with the
lug y, on the shaft /. As the amount of friction increases or
decreases, the lug /z, will exert more or less pressure on /,,
thus giving a slight motion to the shaft j.
As the arm k is setscrewed to the shaft j, any motion of
the shaft will be imparted to the arm, thus causing the lower
end of the arm to swing. A balance arm k.^ fastened to k
by a shoulder k^ carries balance weights k^, k^. The latter,
which is adjustable, can be moved along the arm k.^ to regu-
late the weight of the sliver to be delivered. At its lower
end, the arm k is connected to a rod /, Fig. 9 {b), that is con-
nected at the point /, to the arm c/^, the latter being a part
of the casting carrying the guard plate d^. When the shaft /
is moved by the movement of the trumpet, it will move the
lower end of the arm k in or out, and thus give a rocking
motion to the casting carrying the guard plate d^, which is
pivoted at ^3.
When the sliver is too light, the trumpet will fall away
from the calender rolls and cause the arm k to move out-
wards, thus exposing the teeth of the gear d to the action
of the pawl ^,, which will cause the evener screw r, to move
the belt to the large end of the top or driving cone, thus
increasing the amoiuit of cotton fed in and making the
sliver heavier. When the sliver is too heavy, the action
will be reversed.
The floor space occupied by a single head of this type is
about 8 feet 2 inches by 5 feet 10 inches, allowing for the
space occupied by the cans at the back. The weight is
about 1,150 pounds, and I horsepower is required to drive it,
while a double head occupies a space of about 6 feet 3 inches
by 5 feet 10 inches, the weight being about 2,000 pounds,
and about \\ horsepower is required.
§21 AND DRAWING FRAxMES 17
Owing to the objects and construction of railway heads
and drawing frames being somewhat similar, the manage-
ment of railway heads resembles that of drawing frames.
Information on this subject can be obtained later in this
Section, where the management of drawing frames is fully
dealt with.
DRAWING FRAMES
INTROD IICTION
11. The drawingr frame is the last machine in which
any extensive correction of the unevenness of the sliver takes
place. It usually follows the railway head in mills that use
the latter machine, except when the stock is to be combed,
in which case it follows the comber. In the most common
arrangement of machines, the railway head is omitted and
the drawing frame follows the card, except when combed
yarn is being made, when it follows the comber.
The objects of the drawing frame are: (1) to lay the
fibers parallel; (2) to correct, as far as possible, any uneven-
ness in the sliver. These objects are accomplished: (1) by
drafting, which by pulling the fibers past one another tends
to make them lie in a parallel position; (2) by doubling,
Avhich has a tendency to even the resulting sliver.
12. Number of Drawing Processes. — At least two
processes of drawing will be found in almost every mill;
that is, a number of cans of sliver that are made at the front
of one drawing frame will be placed at the back of another
frame and run into one sliver at the front of this second
frame. The number of drawing frames through which the
cotton is passed is governed by the class of work to be pro-
duced and the number of preceding processes through which
the cotton has passed. If the sliver comes direct from the
cards there are usually two processes for coarse counts, three
for medium counts, and four for fine counts. If the sliver
has passed through the railway head, each of the above
18 RAILWAY HEADS §21
number of processes is reduced by one process. If the
sliver has passed through the sliver- and ribbon-lap machines
and the comber, there are generally only two processes unless
for very high counts, when three, and even four, are used.
When four processes of drawing are used, the machine
that receives the sliver first is called the breaker, while the
others are named in order first intermediate, second inierrne-
diate, and finisher. With three they are called breaker, inter-
mediate, and finisher, while two are designated as breaker
and finisher. The four processes are also known as first,
second, third, and fourth drawings.
13. Arrangement of Drawing Fi*anies. — Drawing
frames are generally placed directly in front of each other,
the usual method being to place the cans from the card,
comber, or railway head, as the case may be, at the back of
the breaker drawing frame, and as the sliver is delivered at
the front, the full cans are taken and placed at the back of the
next drawing frame, this system being followed through-
out the processes of drawing. Where the floor space is limited,
the frames may be placed in a line instead of in front of each
other, in which case the alternate drawing frames face the
same way. For instance, where three processes of drawing
are used, the cotton is passed through the breaker drawing
frame situated at the end of the line. The cans from the
breaker are then taken to the intermediate, which is facing
in a direction opposite to that of the breaker drawing frame,
while the cans from the intermediate are taken to the third
drawing frame, which is at the other end of the line and has
its delivery on the same side as the delivery of the breaker
drawing frame.
GENERAIi CONSTRUCTION
14. Fig. 10 shows a view of the front of a drawing frame,
the construction of which very closely resembles that of a
railway head, with the exception that no evener motion is
attached. One complete drawing frame is called a head.
Several heads, however, may be connected by one shaft and
21
AND DRAWING FRAMES
19
20 RAILWAY HEADS §21
still be called a drawing frame, or more accurately, a line of
drawings. Each head consists of a number of deliveries,
while each delivery has its own coiler and its own set of
drawing rolls, which receive a number of slivers at the back,
subject them to the desired draft, combine them into one
sliver at the front, and deposit it in a can. For example, if
four, six, or eight slivers side by side are passed through
four sets of rolls and combined at the trumpet at the front
of the machine into one sliver, that part of the machine is
called a delivery, and a number, or set, of these deliveries
is called a head.
A line of drawings usually consists of three heads, while a
head may contain from four to eight deliveries. Fig. 10
represents a drawing frame with one head of six deliveries;
if, however, the lower shaft were extended and another
pulley mounted on it to drive another set of gearing, which
in turn governed six other deliveries, it would represent
a line of drawings consisting of two heads with six
deliveries each.
Fig. 11 represents a cross-section of one delivery of the
machine shown in Fig. 10; the arrows in this figure indicate
the direction in which the stock passes through the machine.
Usually six cans similar to a are placed behind each delivery,
each sliver passing through the guide b, over the plate r, and
the spoon d, there being one spoon for each sliver. The
slivers next pass over another guide plate e and then to the
four sets of rolls /, /,, Z^, /a, where the necessary draft is
inserted. From these drawing rolls the slivers pass to the
trumpet g, where they are combined into one, then through
the calender rolls //, //,, through the coiler tube z, and to the
can y. The guide b consists of a number of fingers, between
each two of which a separate sliver passes; in this manner
the sliverr are prevented from licking or splitting. The
plate c is highly polished, thus preventing the fibers from
adhering to it, while it also forms a cover for the working
parts beneath. The guide e consists of a casting carrying
two projecting lugs, the distance between which is about
equal to the width of all the slivers passing through the
22 RAILWAY HEADS §21
delivery. This guide is secured to the plate ^, by two screws
similar to e^.
The drawing rolls are of the ordinary type; leather-covered
top rolls are shown in this illustration, although for coarse
work metallic rolls are generally preferred. The length of
the top rolls for each delivery varies from 15 to 18 inches,
while each bottom roll is generally made in one length for
the whole head or, as in more modern construction, in
sections pieced together so that they revolve as one roll.
The top rolls are weighted in the manner usually adopted
for weighting leather-covered rolls on drawing frames. The
weighting arrangement is equipped with a weight-relieving
motion, as shown at /, /,, /j, h. The draft inserted in the
sliver by these rolls, though not arbitrary, is usually about
equal to the number of doublings, thus producing a sliver at
the front of about the same weight as each end fed in at
the back.
The trumpet g is supported by the lever g^ and derives its
name from being trumpet-shaped. It occupies a nearly
upright position, having the smaller part of the hole at the
delivery end. The sliver enters the larger end of the trumpet
and is condensed by being drawn through the smaller part.
The calender rolls //, //i are smooth steel rolls extending
along the machine parallel to one another, and to the front
rolls. The rear roll //, is about 2 inches in diameter, while
the front one h is slightly larger. These rolls are solid and
self-weighted, and serve to condense the sliver and draw it
through the trumpet g. Their surface speed is just sufficient
to prevent any slackness of the sliver as it comes from the
front rolls. The coiler connections at the front of the draw-
ing frame are very similar to those attached to the card.
The oblique tube / is connected to the plate /,, which has
teeth on its rim and is driven by the gear ?'=; the gear i^ is
compounded with the bevel gear /a, which is driven by the
bevel gear /« on the shaft i^. This shaft extends the entire
length of the machine and has at each delivery a gear similar
to z*, which drives the gears that give motion to the coiler
for that delivery.
§21 AND DRAWING FRAMES
23
15. The diameters of the cans into which the sliver is
delivered at the front vary from 9 to 12 inches, advancing by
inches, those generally used being 10 inches in diameter. In
former years they were made wholly of tin, but those now
used are generally made of a paper pulp, which has the
advantage of being lighter and cheaper. Although lighter,
they are more durable than the metal cans, and seldom show
the principal defects of the latter type of can; namely, ragged
edges and loosened or detached bottoms.
STOP-MOTIONS
16. The principal parts of a drawing frame that call for
a somewhat more detailed description are those connected
with the various stop-motions. If one of the cans at the
back should become empty or if one of the slivers should
break before reaching the back rolls and the machine should
continue to run, the reduced weight of the sliver delivered at
the front would tend to produce unsatisfactory work at the
later processes. As it is of vital importance to have the
sliver that comes from the drawing frame of a uniform
weight, devices are applied to stop the machine when an end
breaks or runs out at the back. Additional motions are also
applied to stop the machine when the sliver breaks between
the front rolls and calender rolls, when the cans at the front
of the machine become full, and in some cases when any
part of the cotton laps around the calender or the draw-
ing rolls. There are two general classes of stop-motions
applied to drawing irsime?,—mecha7iical and electrical. As the
mechanical stop-motions are older and more commonly met
with, they will be described first.
MECHANICAL STOP-MOTION
17. The method adopted to automatically ship the belt
from the tight to the loose pulley and thus stop the machine
will be described with reference to Figs. 11, 12, and 13,
Fig. 12 being a plan view and Fig. 13 a sectional elevation,
taken on line x x oi Fig. 12. The driving belt runs on the
24
RAILWAY HEADS
21
tight and loose pulleys z/, //,, Fig. 12, and is governed by the
belt guide r, which is fastened to the rod q and extends out-
wards above the spring ^ and shaft k^. Working loosely on
. Fig. 12
this rod is the casting q^, which is kept pressed against the
belt guide by means of the spring s, one end of which is
fastened to the bracket /, while
the other end is connected to the
arm q. of the casting q^, this arm
working loosely on the shaft k^.
By this means the casting q^, un-
less held in position by some
other mechanism, will force the
belt guide r in such a direction
that the belt will be shipped from
the tight pulley ii to the loose
pulley Ui.
The method adopted to hold
the casting q^ in position when
the belt is on the tight pulley is
Pivoted at the point p^ is
the casting p, which carries two arms p^, p^. When the
machine is started by means of shipping the belt from the
Fig. 13
more clearly shown in Fig. 13
§21 AND DRAWING FRAMES 25
loose to the tight pulley, the belt guide r, Fig. 12, carries
the casting </, along with it as the shipper and rod move.
The projection on the casting g^ is beveled off on the side
that comes in contact with p^ when the belt is being shipped
to the tight pulley. Thus the outer end of p is raised until
the projection on g^ passes the arm ^3, when it falls and
allows p:, to hold the casting securely in position. Set-
screwed to the shaft k^ is the knuckle-jointed lever ?/. The
upper end ;/,. of this lever contains a slot ?/,, in which works
a pin Wi, which is a part of, and revolves with, the gear w.
Thus, as the gear revolves, the pin ;;/, moves the upper end of
the lever alternately backwards and forwards, which imparts
an oscillating motion to the shaft k,, provided that this shaft
is free to oscillate, since under these conditions the fulcrum
of the lever will be at the point at which it is attached to the
shaft. If, however, the shaft X', is prevented from oscillating,
the fulcrum of the lever will be at the point n^, and as the
part 71^ is forced out by the pin w,, the arm 713, which is a
part of Wj, will be forced against the arm p^, pushing up the
casting/", since it swings on/,, and allowing the arm />3 to
release the casting g,.
18. Drawing frames equipped with the mechanical
stop-motions automatically stop when the sliver breaks or
runs out at the back, when the sliver breaks in front, and
when the cans at the front become full.
The manner in which the machine is stopped when a sliver
at the back breaks or runs out is described with reference to
Figs. 11, 12, and 13. Referring to Fig. 11, it will be noted
that each sliver passes over a guide d, known as a spoon^
that is supported at the point d.. but is free to swing up and
down, its lower end being slightly heavier than its upper
end. The weight and tension of the sliver in passing over
the spoon is sufficient to lower the upper end of the spoon.
Should the sliver break or run out, however, the spoon will
be released, its lower end will drop, and the projection di
will engage with a projection on the arm k, which being set-
screwed to the shaft /(.', oscillates with that shaft. As the
26 RAILWAY HEADS §21
projection </, engages with the projection on the arm k, the
shaft ky is prevented from oscillating, thus causing the arm «3,
Fig. 13, to be forced against /j, bringing ^^ out of the path
of ^., and allowing the spring s. Fig. 12, to force the casting
against the belt guide, shipping the belt from the tight to
the loose pulley and stopping the machine.
19. The mechanism that stops the machine in case the
sliver breaks between the front rolls and calender rolls is as
follows, reference being made to Fig. 11. A lever g^ that
is pivoted at g^ carries a weight g^ that tends to lower the
outer end ^9. At its forward end the lever ^3 carries a lug^s
that bears against the lever g^, which in turn bears against
an adjusting screw g., carried by the lever g^ that supports
the trumpet g. In case the sliver is running through the
trumpet properly, the weight and tension of the sliver is
sufficient to cause the lever g,. to hold down the lever g^; and
since this lever rests on the lug g^, the weight g^ will be
prevented from lowering the outer end g^ of the lever g^.
On the other hand, if the sliver breaks at the front of the
machine, the outer end of the lever ^3 is forced down by the
weight, and the part g^ comes in contact with the front of
the projection k^ on the arm k, which action prevents the
shaft k, from oscillating and stops the machine in the manner
previously described.
20. When the can /, Fig. 11, is filled, the sliver gradually
presses the plate /. up, forcing the upper end of the tube i
against the lever ^e, which allows the weight ^4 to forceps
into the path of the projection k., thus stopping the machine
in the same manner as when the sliver breaks at the front.
ELECTRIC STOP-MOTIONS
21. Introcliictory. — A principle that has been exten-
sively applied to drawing frames is that of automatically
stopping the machine through the use of electricity. But in
considering electric stop-motions it will first be necessary
to give some attention to certain laws of electricity that
§21 AND DRAWING FRAMES 27
make it possible to apply this class of stop-motions to cotton-
mill machiner3\
The electric current must always be generated by some
suitable apparatus, which for stop-motions on drawing
frames generally consists of a dynamo placed above the
frames. If suitable connections are made, an electric current
will flow from one part of the dynamo through the con-
nections and back again to the dynamo, forming what is
known as a circuit. In order to have a current of electricity,
there must always be a complete route, or circuit, from the
source of the electric current through the various connections,
and back again to the place from which it started. If there is
more than one route that the current can follow, it will divide
into two or more separate currents, but the maximum current
will always flow through the path of the least resistance.
If for any reason the circuit is broken, the flow of electricity
will stop. The two ends, at the place where the circuit is
divided, are known as terminals, one of which is termed posi-
tive and the other negative. That terminal from which the
current would flow, if connected with the other terminal, is
called positive; while the terminal into which the current
would flow from the positive terminal is called negative.
Substances are divided into two classes as regards the resist-
ance they offer to the flow of electricity, and are known as
conductors and non-conductors, the former consisting of
those substances through which an electric current can read-
ily pass, while the latter comprises substances that offer great
resistance to the flow. When two conductors come in con-
tact, the current readily flows from one to the other. If it is
desired to prevent this flow, the bodies must be insulated;
that is, they must be separated by some substance that is a
non-conductor. Metals are good conductors, while glass, silk,
cotton, etc. are poor conductors. Thus, if a current of elec-
tricity is passing from one piece of metal to another, as, for
instance, the top and bottom rolls of a drawing frame, and
some non-conducting substance, such as cotton, is brought
between the points of contact of the two pieces of metal, the
circuit will be broken and the current stopped.
28 RAILWAY HEADS §21
If a piece of soft iron is surrounded by coils of wire through
which an electric current passes, the iron becomes magnet-
ized and has the power of attracting certain other metals,
such as iron and steel. A piece of iron magnetized in this
manner is known as an electromagnet.
22. Operation of tlie Electric Stop-Motion. — Fig. 14
is a section of a drawing frame equipped with the electric
stop-motion, while Fig. 15 is a portion of a front view of the
same machine. The electric current passes from the dynamo
through the rod a into and through the several parts of the
machine and leaves it through the rod a^ to enter the dynamo.
As far as possible, the path that the current takes through
the drawing frame has been indicated by means of arrows.
Otherwise, those parts that are connected with the positive
terminal of the dynamo are indicated by being cross-hatched
in two directions, when in section, and by a dark surface
shading, when not in section. Those connected with the
negative terminal are shown in the ordinary manner.
It will be noticed that, with few exceptions, the whole
frame of the machine with all the rolls, except one, are nega-
tive; this positive roll is marked m. Among the positively
charged parts the most important are the cover />,, back
plate >^3, connecting piece X%, roll w, rod k^, and springs /, 5.
It is of importance that the positively charged parts shall
be electrically insulated from those negatively charged. This
is attained by interposing plates or disks of insulating mate-
rial between them. The presence of these insulating parts
at any place is indicated in the drawings by means of full
black surfaces. The action of the stop-motion depends on
devices by means of which connections are made between
the insulated parts, in order that an electric current may pass
from one to the other.
The path of the electric current through the machine is as
follows: From the rod a through the electromagnet b, bi,
then through the parts /, /, k, and the rod ki that extends
across the frame. Electrically connected with this rod are
two springs s, t, these springs being duplicated at each
30 RAILWAY HEADS §21
delivery. From the rod k^, the current passes through the
connecting piece k^ that extends to the back of the frame and
forms a connection with the back plate k^. From here the
current passes to the cover /», and roll yn.
It should be noticed that as long as the various parts are
kept insulated from each other no electric current will pass
through. It is only in case any one of the insulating plates
is, as it were, bridged over that a current will flow. The
current in all cases makes its start through the electromag-
net b, bi', this will therefore always be set in action first
and will attract the small finger c. As this finger is pivoted
at c, its lower part swings over, coming in contact with a
dog d that is a portion of /, which, although loose on the
coiler shaft d^, ordinarily revolves with it, being driven by
frictional contact with the part g, which revolves with the
shaft rt'i, since the surfaces of. these parts that are in contact
are at an angle with the shaft. The part .^ is on a keyway
on the shaft d^; consequently, it must revolve with the shaft,
but is capable, however, of being pushed lengthwise of the
shaft. As d and / are stopped by the finger c, the part g, con-
tinuing to revolve, will be pushed lengthwise of the shaft
because of the shape of the parts f,g. This action of g
throws the lever e to the right, which, since e is fastened to
the shaft e^, gives the latter a partial revolution. Setscrewed
to the shaft e^ is a casting e., an arm of which works in a slot
in the upright rod ^3, which controls the shipper rod e^ to
which the belt shipper is attached. As the shaft e^ is turned
by the lever e, it throws the casting e^ over to one side,
moving the rod <^3 and, consequently, the shipper rod e^ in
such a direction that the belt will be shipped from the tight
to the loose pulley.
The action of the rod // should be noted in this connec-
tion. As the lever e, to which it is fastened, is forced over
by^, it brings with it the rod h, which is so shaped that it
forces the finger c out of contact with the revolving dog d,
thus placing these parts in their initial positions.
Drawing frames equipped with the electric stop-motion
shown in Figs. 14 and 15 stop when the sliver breaks or
32 RAILWAY HEADS §21
runs out at the back, when laps form on the top or bottom
front drawing rolls, when the sliver breaks in front, and when
the cans at the front become full.
23. The rolls m,n are known as the top and bottom pre-
venter rolls, respectively; they are also sometimes called
detector rolls. They are frequently found applied to both
railway heads and drawi-ng frames, and are considered an
advantage both in working the stop-motion when an end
breaks or runs out at the back and in making a piecing at
the back. With these rolls, the tension on the sliver is more
even, thus keeping the spoons in their correct position and
causing the stop-motion to act more quickly. A piecing at
this place is desirable since, as it does not require tall help to
run the frames, small boys, girls, or women may be employed,
whereas when the piecing must be made close to the back
rolls taller help is required.
As shown in Fig. 14, the roll m is positive, while n is
negative; consequently, if these rolls are allowed to come in
contact, a circuit will be formed and the machine stopped.
The lower roll n extends the entire length of the machine,
while the top roll vi is made in shorter lengths, there being
one of these rolls for every two slivers at the back. As long
as the slivers are passing between these two rolls they are
prevented from coming in contact. Should either sliver
break or run out, however, the end of the roll under which
it passes will drop and, coming in contact with the lower
roll 11, will form a circuit and stop the machine. By referring
to Figs. 14 and 15, it will be seen that the drawing rolls
are negative and the covers positive. The front top roll
rests in bearings and is capable of being raised if any
obstruction comes between it and the bottom roll. Fastened
to each cover of the drawing frame are two adjustable
screws, similar to p, that are so set that they will not come
in contact with any part of the rolls so long as the cotton is
running through the machine properly. If the cotton laps
around either the top or bottom roll, the increased size of
the bulk of cotton between the two rolls will cause the top
^21 AND DRAWING FRAMES 33
roll to be raised in its bearings until it comes in contact with
one of the screws p, when a circuit will be formed and the
machine stopped.
The back calender roll r, extends the entire length of the
frame, while the front calender roll r is made in sections,
each of which is only long enough to serve for two deliveries
and rests in inclined bearings. As long as the cotton is
passing between the rolls, the thickness of the sliver will
push the roll r up slightly in its bearings. However, should
either sliver that passes between any one of the front
calender rolls and the back calender rolls break, the end of
the front calender roll that was supported by that sliver will
drop and come in contact with the spring s. As one of these
parts is negative and the other positive, a circuit will be
formed and the machine stopped.
As the can at the front of the machine becomes full, the
pressure of the sliver in the can raises the top of the coiler
until it comes in contact w'ith the spring /, when the machine
will be stopped, owing to a circuit being formed by the
contact of these two parts, one of which is positive and the
other negative.
GEARING
24. Each head in a drawing frame is driven separately
from any other head in regard to its individual gearing, but
all the heads are driven by what is called the lower or main
shaft, which runs underneath the frame; this shaft is shown
in Fig. 10, and also in Fig. 16, which is a plan of the
gearing of the machine similar to that shown in Fig. 10.
At each head is a pulley that is connected with a tight-and-
loose pulley on the front roll of that particular head by
means of an open belt. The lower or main shaft is driven
from the main shaft or countershaft of the room.
Referring to Fig. 16, a gear of 24 teeth on the front roll
drives, by means of suitable gearing, the calender rolls and
the coiler connections. Another gear of 24 teeth, situated
on the front roll, drives the back roll. The gear of 26 teeth
on this back roll drives the third roll. Thus, the draft
34
RAILWAY HEADS
§21
between these two rolls is constant, provided that the gears
connecting the rolls are not changed. The wide-faced gear
of 60 teeth on the back roll drives, by means of a carrier,
the gear m, shown in Fig. 13 but not in Fig. 16, The gear
100 33
MaJTh Shaft
Fig. 16
of 20 teeth on the front roll drives the second roll, and con-
sequently the draft between these two rolls is constant, pro-
vided that the gears connecting them are not changed.
Thus it will be seen that the break draft of this machine
comes between the second and third rolls.
§21 AND DRAWING FRAMES 35
The draft of a drawing frame with common rolls, and
geared as shown in Fig. 16, would be as follows, the draft
being figured from the calender roll to the back roll:
2 X 30 X 24 X 100 X 60
24 X 45 X 24 X 44 X It
= 5.509
MANAGEMENT OF DRAWING FRAMES
25. The arrangement of the cans at the back of the frame
is an important point to be considered. The usual practice
is to place full cans of sliver behind the breaker drawing
frame. This is all right for the breaker, as there is never the
same amount of sliver in the different cans, due to the cards
or combers being separate; therefore, the cans will be
emptied at different intervals, thus insuring that no two
piecings will come together and that the frame will not
remain stopped for any length of time waiting for the
attendant to piece more than one end. This, however, is not
the case wath the first and second intermediates and finisher,
since in this case if a sliver breaks the whole head is stopped,
and consequently when one can is full they are all full, if
empty cans were inserted at the front at the same time; and
if they are all taken out at once and fed immediately to the
next machine at the same time, it is evident that they wnll all
be emptied at about the same time, necessitating several
piecings in a short length of sliver. To remedy this defect,
it is better to feed the frames in sections so that some of the
cans at the back of any drawing frame wall be full, others
three-fourths full, still others half full, and so on.
26. The relative weight per yard of the sliver delivered
to the weight per yard of each sliver fed, depends on the
relation of the number of ends fed, or doubled, at the back
of one delivery to the total draft of the machine. It is the
general plan in the drawing frame not to have the draft
exceed the doubling. That is, if 6 ends are put up at the
back of each delivery, the draft is not generally more than 6.
27. Both top and bottom metallic rolls should receive
careful attention to prevent licking, which is frequently
36 RAILWAY HEADS §21
caused by the flutes collecting and holding the dirt. On
this account metallic rolls require cleaning oftener than
common rolls.
Where common top rolls are used, they should be relieved
of the weights if a stoppage occurs for more than 48
hours. This helps to prevent the leather top rolls from
becoming fluted.
28. Before the leather top rolls are put into the drawing
frame, they must be varnished, the frequency of subsequent
varnishing depending on the varnish used, the weight of
sliver produced, and the speed at which the rolls are run.
Any roughness on the surface of these rolls causes licking,
and careful attention should therefore be given to them, as
licking produces waste, light sliver, and loss in production
•through stopping the head to remove roller laps. Any top
roll that shows impressions of the flutes of the bottom
steel rolls on the leather, or becomes fluted, as it is called,
should be immediately recovered.
29. Sometimes in changing from coarse to fine work, or,
in other words, from a heavy to a light sliver, the trumpet
must be changed. This is on account of the sliver being
so light and the small end of the trumpet so large that the
friction and weight of the sliver will not be sufficient to keep
the trumpet in its proper position, thus causing the frame to
be stopped continually.
30. There should be very little waste made at the drawing
frame, so that if a large amount is made it may be taken as
an indication that some part of the frame is not properly
adjusted, or that the operators are not attending to their
work as they should. The drawing frames should be kept
free from dirt, dust, and short fiber. Oil should not be
allowed in places where it is not required. In order to
insure clean work the tenders should wipe or brush the
frames about every two hours; this takes very little of their
time but greatly helps to improve the quality of the yarn.
A thorough cleaning of all parts of the frame should take
place twice a week.
§21 AND DRAWING FRAMES 37
All bolts, nuts, screws, etc. should be looked after and
kept tight. Stop-motions should be kept in working order,
as otherwise a great deal of bad work will result. All
quickly moving parts, such as the top and bottom rolls,
lower shaft, etc., should be oiled twice a day, and every
moving part of the frame should be oiled once a week, care
being taken not to get the oil on any surrounding parts that
do not require oiling. The boxes of the lower shaft should
be partially filled with tallow.
31. Weighing the sliver at the finisher drawing frame is
a very important matter and should be done at least twice a
day, while in fine work three, and sometimes four, times a day
is advisable. If the weight of the sliver is properly adjusted
at this point, there w'ill be fewer changes in the subsequent
processes. It is also best to have the stock running evenly as
early as possible. The sliver is generally prepared for
weighing by what is known as the measuring board, which
usually consists of two boards 6 inches wide and 36 inches
long hinged together on one of the side edges. One head
of the frame is stopped and the cans at the front taken out.
After it has been ascertained that all the ends are up at the
back, the head is again started and run until about li or
2 yards has been delivered. The machine is then stopped
and the ends of the slivers gathered together with one hand,
while with the other hand they are broken ofif at the top. The
slivers are now placed on one of the measuring boards, care
being taken to have each sliver straight; the boards are then
closed and the ends of the slivers projecting over the two
ends of the board cut with a pair of shears or a sharp knife.
The slivers are now taken from the board and weighed on a
pair of scales. This weight is divided by the number of
deliveries in a head, the result being the average weight of
a sliver for that head. A variation of more than 2 grains
over or under the standard for each sliver should not be
allowed, and if this amount of variation is on the same side
of the standard for two weighings, the draft gear should be
changed. Sometimes the sliver from each delivery is
38 RAILWAY HEADS §21
weighed separately instead of being taken as in the method
previously described.
32. In connection with drawing frames equipped with an
electric stop-motion care should be taken that all the metallic
connections are screwed tightly together, in order that a
circuit may be made and the machine stopped under any of
the conditions previously mentioned. The preventer rolls
should be kept free from oil, since if sufficient oil at any
time collects on either of these rolls, it will form a film over
the surface of the roll, and if under these conditions an end
should break, thus allowing the top roll to come in contact
with the bottom roll, the frame would not stop, as oil is a
non-conductor and prevents the flow of the current. The
contact springs between the calender rolls and coiler top
should be kept clean and free from oil, in order that the current
may not be prevented from flowing from one part to another
when they come in contact. Care should be taken that posi-
tive and negative parts of the frame do not come in contact
with each other when the cotton is passing properly through
the machine, since the current will then return to the dynamo
without passing through the proper channels, in which case
the current is said to be short-circuited. Under this condition
the stop-motion will not accomplish its purpose, and one of the
two following things will happen: If the frame becomes
short-circuited before the current reaches the magnet box, the
stop-motion will not operate when an end breaks, since the
current will be returned through the frame to the dynamo
without passing through the magnet box. If the frame
becomes short-circuited after the current has left the magnet
box, the machine will be stopped, although the sliver may be
running through the machine correctly. In order that the
stop-motion shall operate quickly, which is very desirable, the
finger that comes in contact with the revolving dog should
be within iV inch of the dog when the machine is running.
33, Care of Drawing Frame. — The steel rolls should
be carefully scoured at least once a month. Leather top rolls
should be examined periodically so that the frames will not
§21 AND DRAWING FRAMES
39
continue to run with rolls that are fluted, channeled, or other-
wise defective. Steel rolls that are not running true may
occasionally be found by raising the top clearers and noticing-
whether any of the top rolls are jumping. The top rolls
should be examined frequently to see that the varnishing is
not neglected. The back of each frame requires watchful-
ness on the part of the one in charge to see that the right
number of ends are being fed. Spoons should be examined
periodically to see that they are well balanced and that the
lower end drops immediately when the end of the sliver
breaks or even when it comes through very light; the spoons
should always work easily. Bad piecings should be looked
out for, more especially those that are too long. If the
drawing frame piecing is made 6 inches too long at the
back, that amount of extra material will extend through
many yards of the finished yarn. The guides at the back of
the drawing frame should always be arranged so that the
ends at the back will be separated as widely as the rolls will
allow; bad drawing results if the ends are not spaced suffi-
ciently far apart and one end rides on another.
Occasionally, drawing-frame tenders have been known to
pass cans of material forwards without putting it through the
frame. Where the frame that is skipped has a draft equal to
the number of doublings, this does not make much difference
to the ultimate weight of the yarn, but if the frame is one
where a considerable alteration is made in the weight of the
sliver, the omission becomes serious and causes irregular
work. In any case, the practice should not be allowed.
The covers over the rolls should be examined daily by the
one in charge— or even several times a day— in order to
make sure that the tenders are picking off the clearer waste;
this should be done every hour, for if the waste is left on the
clearer, it is apt to be drawn forwards with the sliver and
cause dirty slubs in the roving and unsatisfactory work at
the future processes. The tenders should not be allowed to
run the cans too full.
It should be remarked in connection with the drawing
frame, as in connection with almost every other machine in
40 RAILWAY HEADS §21
the mill, that high speeds do not always pay. There is a
limit to the capacity of every machine, beyond which the work
done deteriorates, or the excessive number of stoppages,
through breakages and stock running out, prevents any
advantage being gained by an excessively high speed.
In some cases, experiments have been made in connection
with drawing frames in the direction of using fewer processes
of drawing, in order to save labor cost. Drawing is not an
expensive process as regards labor cost, and for this reason
it is not advisable to use less than two drawing frames for
numbers lower than 16s, unless the railway head is also used;
not less than three drawing frames, or one railway head and
two drawing frames, for numbers 16s to 70s; and not less
than four processes of drawing for numbers finer than 70s,
unless the sliver-lap and ribbon-lap machines are used in
connection with the comber. These arrangements are not
absolute and depend on the quality of the yarn desired.
In other cases, experiments have been made with a view to
using extra processes of drawing so as to reduce the number
of processes of fly frames where the labor cost is higher, but
satisfactory results have not always been obtained.
34. The floor space occupied by a drawing frame simi-
lar to the one described and consisting of one head of six
deliveries, is about 10 feet 6 inches by 5 feet 8 inches, allow-
ing sufficient space for six cans at the back of each delivery.
Drawing frames weigh, approximately, 700 pounds per delivery
and, although the horsepower required to drive a frame varies
somewhat with the class of work being run, it may be stated
as a fair estimate that between four and five deliveries
require 1 horsepower.
The speed of the front roll of a drawing frame may be
from 250 to 700 revolutions per minute for a If-inch roll.
The production at 350 revolutions per minute with a 50-grain
sliver, making an allowance of 10 per cent, for stoppages,
is about 168 pounds in a day of 10 hours; with a 70-grain
sliver, about 235 pounds; and with an 85-grain sliver, about
285 pounds.
§21 AND DRAWING FRAMES 41
35. It should be understood that the machines that have
been described do not cover all the makes of railway heads
and drawing- frames, nor do the stop-motions and evener
motions described in connection with the machines illus-
trated include all the different methods adopted to accom-
plish the same objects. However, it may be stated that
the general principles of the different motions will be
found to be similar, and if the descriptions given are fully
understood, there should be no difficulty in tracing the action
of any part of these machines that may be met with under
different circumstances.
COMBERS
(PART 1)
COMBING EQUIPMENT
INTRODUCTION
1. When a cotton yarn is to be manufactured, it is first
essential to select the grade of cotton that is suitable for
the quality of yarn desired, after which it is necessary to
determine the different processes that the cotton must pass
through in order to obtain the required product. This usually
means deciding whether or not the cotton shall be combed.
A lot of cotton, even if of the same grade, will never be
found to contain an absolutely uniform staple, and the fibers
that are below the average length will weaken the yarns
spun from this lot. For very fine yarns, or for a high grade
of yarn even when of coarse numbers, it is customary to
adopt the processes of coinbiiij>: and those incidental to it;
while for coarse or medium yarns, or yarns that are not
required to be of superior quality, the picking and carding
processes are usually considered sufficient for cleaning pur-
poses. In these processes a large portion of the short fibers
remain, but their presence in coarse and medium warp and
filling yarns does not injure the quality to any great extent
so long as the cotton selected is suitable; that is, generally
speaking, in warp yarns that are not finer than 45s and
filling yarns not finer than 90s.
2. Object of CoinbiiipT. — For fine yarns it is essential
that the short fibers should be removed, and to accomplish
J^or notice of cofiyright. see paee immediately followine the title page
i22
2 COMBERS §22
this the process known as combing is introduced. There-
fore, for warp yarns finer than 45s and filling yarns finer
than 90s, or even for coarser numbers than these when a
high grade of yarn is required, it is customary, in addition to
the selection of the proper stock, to remove by the process
of combing all fibers that are not of the required length.
Combing, however, is an expensive operation, as consider-
able waste results from this process, and it is only profitable
to comb when high-grade work is required.
3. In order to distinguish the different processes through
which the cotton has passed, yarns are termed carded
yarns and combed yarns. When yarns are spoken of as
being carded, it may mean that they have been subjected to
one process of carding or that they have been double-carded.
Combed yarns may be single-combed or double-combed, and
in either case they may have been carded once or twice, but
double carding and double combing are not practiced to any
considerable extent.
The process of combing is usually performed immediately
after carding and before the drawing process, although in
some cases one drawing process is used between the carding
and the combing process. With the combing process a
higher grade of yarn than that obtained with the carding
process alone can be made from the same stock, or the
same grade of yarn can be produced from a lower quality
of stock.
4. A combing equipment usually includes three kinds
of machines: (1) the sliver-lap machine, which has for its
object the making of a lap from a number of card slivers;
(2) the ribbon-lap machine, the object of which is to combine
several of the laps from the sliver-lap machine into a firm
and even lap; (3) the comber, the object of which is to
remove all fibers that are under a length suitable for the
yarn required.
When the drawing frame is introduced, the combing
equipment generally consists of drawing frames, sliver-
lap machines, and combers.
§22
COMBERS
SLIVER-LAP MACHINE
CONSTRUCTION AND OPERATION
5. Before the cotton can be combed, it must be placed in
a suitable form for the combing machine, and for this pur-
pose it is taken in cans, either from the card or drawing
frame, to the sliver-lap niacliine, an illustration of which
is given in Fig. 1.
Fig. 1
From fourteen to eighteen cans of sliver are placed at the
back of this machine, the number being governed by the
width of lap required, which is usually Ih 84, or IO2 inches.
The slivers pass from the can, through a guide plate, over
COMBERS
§22
spoons that operate a stop-motion, and then through a suit-
able conductor to the drawing rolls. In Figs. 1 and 2, a is the
guide plate, b the spoons, and <: the conductor. The drawing
rolls d consist of three pairs of rolls, and are similar in con-
struction to those of drawing frames. From the drawing
rolls, the sheet of slivers passes between two pair of smooth
calender, or presser, rolls e, where it is pressed into a uni-
form sheet. These rolls are solid and are usually 5 inches
in diameter; the top rolls are weighted by means of weights
Fig. 2
and levers. The bearings of the top rolls are in vertical
slots, thus allowing them to rise if an excessive amount of
cotton comes between them and the bottom rolls. From the
smooth calender rolls the cotton passes over a polished
guide plate / with adjustable sides, and is then wound on a
wooden roll, or spool, //., which rests on the fluted calender
rolls g, and between the two plates h.
The wooden spool is made the width of the lap required,
with a diameter of about 4 inches, and is held in position by
a spindle passing through the hubs of the plates. On one
§22 COMBERS 5
end of this spindle is a double thread, which screws into a
similar thread on the hub of one of the plates. On the
other end of the spindle is a collar and hand wheel, the
distance from the collar to the thread being such that when
the spindle is passed through the plates and spool and
screwed up tight, the spool will be held firmly between the
plates. The plates are supported by racks /, /,, Fig. 1, the
teeth of which engage with gears on the shaft j. The gear
on the shaft / that engages with the rack /, is fastened to
the shaft, while the gear engaging with the rack / is mounted
on a sleeve that carries the disk /,, This disk is secured to
the casting j^ in such a manner that it is adjustable, while
the casting j^ is keyed to the shaft j. This method of con-
necting the different parts provides a means of adjusting
the rack / with relation to the rack z,. When the racks
are down in position, the spool rests between the upper
parts of the calender rolls g and is in contact with both
of them. The spool is usually made tV inch longer than
the rolls, so that the plates will not bind on the edges of
the rolls. As the fluted calender rolls revolve, the spool
and plates revolve with them; by this means the sheet of
sliver is wound on the spool and the lap formed. The
diameter of the plates is greater than that of the full lap
required, and, being in contact with the ends of the spool,
the lap is built up the same width as the spool, with
perfect sides.
A full lap should be from 12 to 14 inches in diameter,
should have straight, smooth sides, and be hard and firm.
To remove a full lap the friction is released by pressing
down on the friction lever j^ and the racks slightly raised by
the hand wheel 7, on the shaft j. The spindle is then
removed by unscrewing it from the plate and withdrawing it
from the spool, allowing the lap to be rolled on to the table r.
The firmness of the lap is governed by the amount of friction
placed on the friction motion of the racks; the smoothness
of the sides, by the position of the conductor c and the
adjustable sides of the guide plate /. The sides of the con-
ductor c should be so adjusted that the sheet delivered to
6 COMBERS §22
the calender rolls will be somewhat wider than the lap
required. A selvage is formed on each side of the lap by
the guide plate / and the circular plates //.
6. Stop-Motions. — There are two stop-motions, one to
stop the machine when an end of sliver breaks at the back
and the other to stop the machine when the lap is full.
7. The sliver stop-motion consists of unevenly bal-
anced spoons b, the bottom ends of which are heavier than
the top. Each spoon is so adjusted that the weight of the
sliver holds down the upper part. When an end breaks and
passes over a spoon, the spoon is released and the lower end
comes in contact with a tumbler, or rocker. The shaft is
stopped, and a catch on a shipper rod being released, a
spring forces the rod outwards, causing the belt to be
shipped to the loose pulley.
8. The full-lap stop-motion is operated as follows: As
the rack is raised by means of the increased diameter of the
lap, a dog on one of the racks comes in contact with a rod
that extends back and connects with the catch on the shipper
rod. As the dog passes the rod, it causes it to be moved
backwards and releases the catch on the shipper rod. The
dog is adjustable on the rack, so that different sizes of laps
may be made.
9. Settings. — The setting points and adjustments on a
sliver-lap machine are as follows: The proper adjustment of
the stop-motion spoons, so that the spoon will act immedi-
ately when an end breaks; the regulation of the distances
between the centers of the drawing rolls; the proper adjust-
ments of the sliver conductor and guide plates so that a good
selvage will be made; and the proper adjustment of the racks
so that they will be perfectly plumb and level, since, if the
racks are out of level, it will cause the plates to bind on the
edges of the fluted calender rolls and will make an imperfect
lap. The brake shoe on the friction motion also needs
attention, and care should be taken not to allow oil to get
on it.
^ BackRolf
/h'Dia.
22%
SecoHfl
4"
Front
33
41B P 26
21
21
21
r,o
3 "Dia.
S/noof/i Calender Roll
5 'Dia.
Smooth CalenderRoll
12%
/2"Dia.
Fluted CalenderRoll
12"Dia.
riided CaleruferRoll
Fig. 3
8 COMBERS §22
10. Fig. 3 is the plan of gearing for a sliver-lap machine;
the draft, figured from the front fluted calender roll to the
back drawing roll, is as follows:
12 X 21 X 12 X 72 X 21 X 26 X 24 X 64
21 X 72 X 29 X 21 X 50 X 41 X 33 X H
= 1.954
The amount of draft is usually from 1.75 to 2.5. The
weight per yard for a 72-inch lap for medium numbers is
from 230 to 300 grains if it is to be used on the ribbon-lap
machine, and from 200 to 250 grains if for use on the comber.
The 5-inch calender rolls of the sliver-lap machine make
from 50 to 100 revolutions per minute, and the machine pro-
duces from 400 to 950 pounds per day, allowing 10 per cent,
for stoppages. The weight of a sliver-lap machine is about
2,200 pounds, while the floor space occupied is about 5 feet
32 inches by 3 feet 1 inch. About 1 horsepower is required
to drive it.
RIBBON-LAP MACHINE
CONSTRUCTIOM AND OPERATION
11. Object. — It is not absolutely necessary to use a
ribbon-lap macliine in the combing process, as the laps
from the sliver-lap machine may be taken directly to the
comber. If, however, the lap from the sliver-lap machine
is unrolled for about a yard and held to the light, it will be
seen that the slivers merely lie side by side, and that the lap
is uneven, showing both thick and thin places. Therefore,
to have a more even lap, the ribbon-lap machine is used.
The usual doubling on the ribbon-lap machine is 6 into 1,
and the laps fed are generally 1 inch narrower than the laps
to be made for the comber.
12. A view of a ribbon-lap machine is shown in Fig. 4;
Fig. 5 (a) and (b) shows sections through the machine. The
laps from the sliver-lap machine are placed on the wooden
rolls a, a,, Fig. 5 (a), and the sheet passes over the plate d,
which acts both as a guide and stop-motion. On the under
10
COMBERS
§22
side of this plate is a hook that acts similarly to the bottom
part of the spoon described in connection with the sliver-lap
machine. There is a slight draft between the wooden lap
rolls and the back drawing rolls, and as the sheet of cotton
passes over the plate by the tension serves to hold it down.
If the lap breaks or the spool runs empty, the plate rises and
stops the machine.
The sheet passes from the plate b through the guides c to
the drawing rolls d, </,, d^, d^. The cotton then passes through
these drawing rolls, of which there are usually four pair,
the diameter of the first, third, and fourth, counting from the
front of the machine, being \\ inches, and that of the second,
If inches. The draft between the front and back drawing
rolls usually about equals the doublings. The drawing rolls
are constructed similarly to the rolls of dra;wing frames.
The top rolls are weighted by dead-weights, two weights
being used on each roll.
§22 COMBERS 11
From the front drawing roll, the sheet of cotton passes
over a curved plate c. Figs. 4 and 5, to the table /, along
which it passes at right angles to the direction in which it
passed through the drawing rolls. The cotton, in passing
from the curved plate to the table, passes between the
calender rolls g, which are known as the table calender
rolls. In front of each pair a guide finger is placed on
each side of the table to prevent the sheet from spreading.
Each sheet, in passing from the driving end of the machine
to the lap head, is carried under the sheet that is next to
it in the direction of the lap head. The table calender rolls
serve to condense the several layers of cotton into one sheet
and to pass it forwards. From the last pair of table calender
rolls, the sheet passes to the smooth calender, or presser,
rolls of the lap head.
The curved plates e, over which the cotton passes from the
drawing rolls to the table, are very highly polished. In
some cases the plates are nickel-plated, and in others they
are covered with thin sheet brass,' sheet brass taking a
better polish than cast iron, of which the plates are made.
It is necessary that these plates be kept clean and polished,
as the least particle of dirt or oil on the plates will cause the
ends to break, and as there is no stop-motion on this part of
the machine, it will continue to run until stopped by the
attendant, thus causing uneven laps and considerable waste.
The lap head is constructed similar to the one on the sliver-
lap machine, and the passage of the cotton through it is
exactly the same as in the sliver-lap machine.
It is necessary that the table calender rolls, table, and lap
head be perfectly level and in line; if they are not, there will
be some difficulty in getting the several sheets to run to the
lap head properly.
13. Settings. — The points of adjustment and setting
are the same as on the sliver-lap machine. The plate for
the stop-motion should be correctly balanced; the distances
from center to center of the drawing rolls should be properly
regulated; the guides should be so adjusted as to make the
12
COxMBERS
§22
]l0ii-i^pu9injpaini
Csl
'Ufff„C
not/ J'>m''>itK)
lion
^ japuJiUQ
§M
¥
§22 - COMBERS 13
sheets of the desired width; and the racks and friction
motion of the lap head should be set correctly, as mentioned
in connection with the sliver-lap machine.
14. The speed of the 5-inch calender rolls of the ribbon-
lap machine is from 80 to 110 revolutions per minute. The
production varies from 600 to 1,100 pounds per day of
10 hours with 10 per cent, allowed for stoppages. This
machine weighs about 4,500 pounds with all w&ights attached,
and requires 1 horsepower to drive it. The floor space
required is about 14 feet 2 inches by 4 feet.
15. Fig. 6 is the plan of gearing for a ribbon-lap machine;
the draft, figured from the front fluted calender roll to the
back drawing roll, with a 50-tooth draft gear, is as follows:
12 X 30 X 21 X 14 X 20 X 68 X 100 X 70
30 X 50 X 21 X 40 X 72 X 25 X 50 X I2-
= 5.923
SINGLE-NIP COMBER
CONSTRUCTION AND OPERATION
16. The comber is employed to select, from cotton that
has been carded, the fibers suitable for the class of yarn
required. In addition to removing the fibers that are below
the standard length, it combs the fibers to be used and makes
them lie in parallel positions. It also takes out neps, dirt,
and foreign matter that were not removed in the previous
processes. The combing machine commonly used, which
depends on a combination of somewhat intricate movements
for the attainment of its objects, was invented by M. Heil-
mann, of Mulhouse, in Alsace, German}^ Although numer-
ous improvements have been added by other inventors, it is
still spoken of as the Heilmann comber.
A comber is divided into several sections, called heads;
and as now constructed usually contains six or eight heads,
although it may be constructed with a larger or smaller num-
ber, as required. Each head is complete in itself and receives
14 COMBERS §22
one of the laps deliv^ered by the ribbon-lap machine, but the
motions for all the heads derive their power from the same
source. While each head is complete in itself, correspond-
ing parts of each head must act at the same time, the results
obtained depending on the accuracy with which the corre-
sponding parts of each head work together.
17. Passage of the Stock. — Briefly stated, the laps
from the ribbon-lap machine are placed on lap rolls and are
fed intermittently by a pair of feed-rolls. When the laps
from the ribbon-lap machine are used, they should not weigh
more than 300 grains per yard, and when laps are used that
come directly from the sliver-lap machine, they should not
be heavier than 260 grains per yard. The fringe of cotton is
gripped by a pair of nippers, which holds it in such a posi-
tion that it will be acted on by a cylinder having a portion
of its circumference covered with steel points. These points,
or needles as they are called, remove short fibers, neps, and
foreign substances that were not removed in the previous
processes; this waste is then taken from the needles by a
revolving brush and ultimately arrives at the waste can.
During this operation, the fringe of cotton that is being
combed is entirely separate from the fringe of cotton previ-
ously combed, and therefore, in order to have the product
delivered in a continuous sliver, it is necessary to detach the
newly combed fibers from those not combed, and also to
bring back a portion of the cotton previously combed so that
it may be pieced up with the fibers that have just undergone
the combing operation. After piecing-up has been effected,
the cotton just combed is carried forwards and the rear ends
of the fibers receive a combing action by means of a top
comb, which tends to remove still more short fibers. This
cycle of operations is then repeated with a new group of
fibers, resulting in the production of a continuous web of
combed fibers, which is drawn through a trumpet that con-
denses it into a sliver and is then delivered on a table,
together with similar slivers from the other heads of the
comber. From the table the cotton passes through a
I
JL
Fi
I
"I i —
t
§22 COMBERS 15
draw-box and then through a trumpet that condenses all the
slivers into one, which is placed in a can by a coiler similar
to that used on the card.
18. Principal Motions of the Comber. — The several
actions of a comber must necessarily work intermittently, as
it would be impossible to run a lap of cotton continuously
and to draw a comb through it. For this reason the tuft of
cotton being combed must be held firmly at the time of the
combing, first at one end and then at the other, and in order
to do this, the feed must be stopped. The various motions
may be summarized as follows: (1) The feed-motion, by
which the lap is fed to the machine; (2) the nipper motion,
which holds the cotton during the combing operation; (3) the
combing operation by the half lap; (4) the backward and
forward motion of the delivery roll, or the piecing-up motion;
(5) combing by the top comb; (6) the delivery of the stock
to the calender rolls, draw-box, and coiler.
FEED-MOTION
19. Views of a comber are given in Figs. 7 and 8, and
a sectional view is shown in Fig. 9. It will also be of advan-
tage in studying the different parts of the comber to make
frequent reference to Fig. 27, which shows a plan of the gear-
ing of this machine. In describing the comber it will only be
necessary to deal with one head, as each head performs the
same work. The lap b, Fig. 9, is placed on the lap rolls a, a,,
and, as it unrolls, the sheet passes over the apron a^ to a pair
of feed-rolls r. r,. The apron a^ rests at an angle of about 45°
and terminates a little above the nip of the two feed-rolls c, c,.
The apron may be so adjusted that it will assume a greater
or less angle, and it is also possible to regulate its dis-
tance from the feed-rolls. This apron is usually made of
sheet iron, its upper surface being polished or tinned so that
there will be as little friction as possible on the cotton. The
lower edge of the apron carries a brush, the ends of the
bristles of which just touch the bottom feed-roll and keep it
clean. This brush is adjustable in such a manner that the
16
COMBERS
22
correct contact of the ends of the bristles and the bottom
feed-roll may be maintained as the brush wears.
20. Feed-Rolls. — The lower feed-roll c is constructed
in one piece and is long enough to serve for all the heads.
It is fluted in sections corresponding in number to the
number of heads of the comber. Each section, or head, has
a top roll f,, which is slightly longer than the width of each
lap. This top roll is made of steel and is fluted to corre-
spond with the flutes of the lower roll. It resembles a
metallic roll, with the exception that it has no collars; its
flutes also have a little finer pitch. It is held in direct
contact with the bottom roll by means of an arm r^ and a
spring ^3, as shown in Fig. 9, and receives motion from
the lower roll. The lower feed-roll is usually about f inch
in diameter. The objects of these feed-rolls are: (1) To
revolve and deliver a certain length of cotton to the combing
mechanism; (2) to stop revolving after the desired length
has been delivered and to remain stationary while the
combing action takes place.
^22 COMBERS 17
The method by which the feed-roll receives an intermittent
motion is shown in Fig. 10. The feed-roll receives its
motion from the cylinder shaft o^y in the following manner.
The gear b is fast to the cylinder shaft and carries a disk
plate To from which a pin <-« projects. A short distance from
the center of the cylinder shaft is a stud carrying a star
gear c^. The pin d engaging with the teeth of this star gear
turns it during a part of a revolution of the cylinder shaft.
The star gear is so constructed that after the pin has
engaged with one tooth and turned it, the next tooth will be
in position to engage with the pin at the next revolution
of 0^. Compounded with the star gear c^ is a gear c^ that
meshes with a gear c on the lower feed-roll c. Thus, it will
be seen that for every revolution of the shaft Os the feed-roll
is turned a portion of a revolution and the cotton fed to that
extent. This intermittent action of the feed-rolls is trans-
mitted to the lap rolls, as the lap rolls are driven from the
lower feed-roll.
NIPPERS
21. The fringe of cotton that is fed by this intermittent
action of the feed-rolls passes forwards to the mechanism
that holds it during the combing process, which is known as
the nippei's. By a combination of levers, the nippers are
made to act in such a manner that they open to receive the
cotton delivered from the feed-rolls and then close and grip
the cotton after it has been passed to them. They again
open and release the cotton after it has been combed by the
half lap and remain in this position until the next portion of
cotton has been delivered to them. The nippers and their
attached levers are shown in Fig. 11, reference being made
to this figure and also to Fig. 12 in the following description.
22, Cusliion Plate. — The nippers are composed of
two separate parts, both capable of being moved. The
lower part // consists of what is known as the cushion
plate, Fig. 11. It consists of a flat metal plate slightly
longer than the width of the lap. The round nose //, of
the plate. Fig. 11, is usually covered with a strip of leather
18
COMBERS
§22
similar to that used for covering rolls, and is fastened by
metal strips h^, h,. This leather acts as a cushion and
prevents the fibers from being injured when pressed against
f^ww
the plate. The cushion plate is made fast to the frame i by
means of three screws, which are inserted on the under side
of the plate; one of these screws //^ is shown in Figs. 11, 12,
and 13. In some cases the cushion is applied to the nipper
^22
COMBERS
19
knife in place of the plate. When this is done a strip of
leather about -A inch thick and f inch wide is used, and is
fastened to the nipper knife by a strip of steel and small
^i! ^ ^ 1 1^; cg^
screws, the lower part of the steel strip acting as the over-
hanging lip of the nipper knife.
23. Nipper Knife.— The upper part dd., of the nippers
in Fig. 11, is known as the nipper knife. It consists of a
20 COMBERS §22
flat bar of steel; the lower edge is usually fluted and has an
overhanging lip di. The nipper knife is supported by two
arms e, Fig. 11, which are connected to the frame / by the
shaft Ci. Two stands and brackets /, /,, Fig. 11, support
the Jrame i by means of studs i^. As the cotton must be
gripped between the nipper knife d and the cushion plate h,
it is evident that these parts must have a movement that will
change their position from that shown in Fig. 11. This is
accomplished by the movement of the nipper knife.
As shown in Fig. 11, the arms e extend beyond e^ in the
direction opposite to that of the nipper knife. This forms a
connection for the rod g, Fig. 12, that is connected to the
lever g^, while this lever is connected to the shaft g^.
Extending from the shaft g. is an arm g^, the end of which
carries a cam-bowl that works in the cam-course of the
cam g^ on the shaft/, known as the cam-shaft. The shaft g^
runs the entire length of the heads, and the nipper rods g
for each head are connected to it by the method shown.
The shaft g^ receives an oscillating motion from the cam
and, in turn, imparts a similar motion to the shaft (?, of each
head. The arms e being connected to this shaft, the nipper
knife will rise and fall, its lowest and highest positions being
indicated by the full and dotted lines in Fig. 12.
When the nippers receive the cotton, they are in the posi-
tion shown in Fig. 11, but as soon as the proper amount has
been fed, the nipper knife descends, through the action of
the cam, and firmly grips the fringe of cotton between itself
and the cushion plate, the cushion plate at this point being
in the position shown by the dotted lines in Fig. 12. When
the knife has securely gripped the fringe of cotton, however,
the cushion plate is not in the proper position to allow the
cotton to be combed, and it must be lowered so that it will
assume the position shown by the full lines in Fig. 12. In
order to accomplish this, the knife, which has not reached
the full extent of its travel when it comes in contact with the
cushion plate, is forced farther down by the cam and carries
the cushion plate with it. The cushion plate is capable of
being forced down, since it is suspended by the studs z^,
I
22
COMBERS
21
Fi<j. 11, which project from the frame / and have bearings
on the bracket /. connected to the stand /. Thus, the entire
frame / can swing on the studs /, and cause the cushion
plate // to come nearer the cylinder. By this movement the
cushion plate and the front lip of the knife are brought close
to the needles, thus enabling the cotton to be combed very
close to the grip.
As the nipper knife is raised by the action of the cam, the
swing frame / is brought back to its original position by
means of the springs /s, Fig. 11. These springs are always
tending to pull the cushion plate up, but when the knife
moves downwards, the tension of the springs is overcome by
the positive motion of the knife received from the cam. The
position of the cushion plate when the knife is not pressing
on it is governed by the distance that the setscrew ?3 projects
through the bracket /,. The setscrew comes in contact with
the stand / and prevents the swing frame from moving any
farther, but the knife continues to rise and thus the nipper is
opened and the fringe of cotton released.
24. As the needles o-, shown in Fig. 15 pass through the
fringe of cotton projecting beyond the nippers, there is a
22
COMBERS
22
tendency of the lap to spread, which is also increased by the
operation of the feed-Tolls. In order to avoid this spreading,
a device is used on the cushion plate, a view of which is given
in Figs. 13 and 14. It consists of a plate /u placed at each
end of the cushion plate. These plates carry two projecting
pieces h,, h^, between which the nipper knife descends,
/?, being curved so that the knife will not come in contact
with it. By this means, it is practically impossible for the
lap to spread when being combed.
Fig. 14
COMBING OPERATION BY THE HALF LAP
25. Cylinder. — The cylinder consists of three principal
parts — the central stock, or barrel, Oi, Fig. 15, the half
lap Oi, and the fluted segment o^ — the other parts o^ and ^5
being known as niaking-up pieces. The central stock is
secured to the cylinder shaft 0^ by means of screws. The
outside of this stock is shaped so as to receive the half lap
and the fluted segment, which are secured to it by screws, as
shown in Fig. 15. The half lap is composed of two parts —
the comb stock and the matrices. The comb stock is formed to
receive a series of matrices, or strips, 0^, to which are fastened
seventeen rows of needles o, made of round steel tapered to a
§22
COMBERS
23
point. These needles are so spaced that their number varies
from thirty to ninety per inch, while the diameter decreases as
the number per inch increases; thus, the needles in the front
row of the half lap — that is, those that come in contact with
the cotton first — are the most widely spaced, and are also of
the largest diameter; the number of needles in the succeed-
ing rows increases, until the finest spacing, that is, the
largest number per inch, occurs in the seventeenth row, in
which there are ninety needles per inch, the needles in this
row being also of the smallest diameter. For medium work,
the number of rows of each number of wire from which the
needles are constructed is as follows, commencing with the
front row of the half lap and following in the order named:
Four rows of 20s, three rows of 22s, two rows of 24s, two
rows of 26s, two rows of 28s, three rows of 30s, and one row
of 33s. For very fine work, the arrangement of the needles
24 COMBERS §22
is sometimes as follows: Six rows of 22s, three rows of 24s,
two rows of 26s, two rows of 28s, two rows of 30s, and two
rows of 33s.
When setting the needles they are placed in a gauge, point
down. The matrix to hold them is placed against the row of
large ends while the needles are in the gauge and they are
then soldered to the matrix, after which the gauge is removed.
The matrices to which the needles are attached are usually
made of brass and planed and shaped so as to lie accurately in
their proper positions, in order to give the needles the correct
angle when they are secured by the setscrews that hold them
to the comb stock. By having the half lap constructed in this
manner, it is a simple matter to remove it from the machine
when a row of needles becomes injured, and then by remov-
ing the matrix the damaged needles may be readily replaced.
In addition to having the rows of points of the needles in the
half lap concentric, each row of needles should be exactly par-
allel with the cylinder shaft. The width over all of each row
of needles is usually a little in excess of the width of the lap,
so that the edges of the lap will receive an effective combing.
As the cylinder shaft on which the half lap is mounted is
constantly revolving, it will be seen that each fringe of cotton
gripped by the nippers will be subjected to the action of the
half lap. This action takes place immediately after the
cotton has been gripped by the nippers and the cushion plate
has been forced down by the nipper knife. The half lap is
placed on the cylinder in such a position that the largest and
heaviest needles are caused to act first on the fringe of cotton
to be combed, in order that they may do the heaviest work
and make it easier for the finer needles that follow and give
a more effective combing. Any fibers that are not held
firmly by the nippers are combed from the fringe of cotton,
so that only fibers of sufficient length are left. In addition
to these short fibers, dirt and neps are also removed, while
the fibers held by the nippers are combed out and laid parallel.
The short fibers and foreign matter that are removed from
the fringe are carried by the needles of the half lap until the
brush p. Fig. 9, removes them and deposits them on the
§22 COMBERS 25
doffer r, which works at a much slower speed than the brush.
The doffer has its surface covered with a clothing, composed
usually of leather, having heavy wire teeth inserted in it at
an angle. The doffer is not in direct contact with the brush,
but as the brush revolves, the centrifugal force throws out
the short fibers, and the needles of the doffer are thus enabled
to secure them.
26. The Doffer Comb. — As r revolves, the waste is
stripped from it by means of a comb r^ that acts on the
same principle as the doffer comb of a card. The waste
then drops into a can, there usually being one can for two
heads. In some cases, however, the waste is wound on a
roll. At the back of the cylinder, brush, and part of the
doffer there is a tin cover />3, Fig. 9, which is of a special
shape, made in one piece and called the brush tin. Another
cover, known as the waste chute, covers the cylinder and
brush on the other side, and is shown at />«. These covers
prevent the escape of waste and also act as a protection
against any foreign substance coming in contact with the
moving parts.
PIECING-UP MOTION
27. After the cotton has been combed and the nippers
opened, the fringe of cotton comes under the action of the
pieciiig-up uiotion. It should be understood that the
fringe of cotton being combed is not connected to the cotton
previously combed, and in order to have a continuous sliver,
each fringe of cotton is pieced up to the cotton immediately
in front of it. In order to accomplish this, a portion of the
previously combed cotton must be returned, while the fringe
must be in a position to be attached to it and carried forwards.
It is the object of the fluted segment, which is a part of
the cylinder, to support the fringe of cotton that has just
undergone the combing action. The finely fluted surface of
the segment is at such a distance from the center of the
cylinder shaft that it can come in contact with the under
side of the combed fringe and thus support it until it is
detached. A view of the segment supporting the fringe is
26
COMBERS
§22
shown in Fig. 16. When the fringe is held in the position
shown, the operation of piecing-up and detaching is per-
formed by three rolls q, s, t; g is sometimes termed the
leather detaching ?vll; s, the steet detaching jvll; and t, the
brass roll. In other instances t is called the piecing roll. In
this Section, however, g will be known as the leather detach-
ing roll; s, the delivery roll; and /, the top roll. These
names are strictly in accordance with the duties and positions
of the rolls, as g de-
taches the cotton, and,
although 5 assists in
this operation, its
chief function is to
deliver the cotton
after it has been de-
tached. The roll /
also aids in delivering
the cotton, and as it
is directly above the
delivery roll, it may
be termed the top roll.
28. The delivery
roll ^ is made in one
piece long enough
to serve for all the
heads. Opposite
each head is a fluted
section, the flutes
usually being spaced
differently from those
of the feed-roll. When a lap 82 inches in width is used, the
fluted section is generally 11 inches wide and contains about
fifty flutes for each inch of diameter. The diameter of the
roll is usually f inch. The roll revolves in bearings on the
framework and is in such a position that it is just clear of
the needles of the half lap and the segment. The parts of
the bearings in contact with the roll are usually made of brass.
Fig. 16
§22
COMBERS
27
29. The leather detaching: roll q. Fig, 17, is in con-
tact with the delivery roll. The leather portion of the
detaching roll is slightly wider than the fluted segment of the
Fig. 17
cylinder and resembles a top roll of the common type, being
shown in Fig. 18. The boss of the roll is generally about
r-Htnrto
' Fig. ]8
10^^ inches in length and It inch in diameter. The skins
used for covering should be of the finest quality, as so few
28
COMBERS
22
fibers are dealt with that any irregularity of the roll produces
bad work. This roll has brass bushings q,. Fig. 18, for
bearings, which are supported by the blocks Z^, Fig. 17.
is shown in this figure.
The bushings are held in place
against the blocks by means of
weight hooks q., connected to the
weights, as shown in Fig. 19, the
hooks having a direct pressure on
the brass bushings of the leather
detaching roll. This keeps the
leather portion of the detaching
roll pressed against the delivery
roll, and when the comber is to be
stopped for any length of time,
the pressure should be relieved by
placing the arms q^, Fig. 19, of the
hooks ^2 on a rod that extends the
length of the heads. This prevents
the leather from becoming injured
during the time that the machine
is not in action. The blocks h,
Fig. 17, with which the bushings
are in contact, are supported by
means of brackets /j, one of which
Each head requires two of these
brackets, which are fast to the shaft /,, which is long enough
I
§22 COMBERS 29
to serve for two heads and consequently to support four
brackets. The shafts have bearings on the framing of the
comber and are capable of being moved. The brackets, with
their connections, are known as the horschcad, or lifter.
30. The top roll /, Fig. 17, is generally constructed of
brass and contains flutes that correspond to the flutes of the
delivery roll. The fluted section, however, is usually a little
shorter than the fluted section of the delivery roll. This roll
is supported by brackets /,, fast to the shaft A, and, as the
bearings of the roll are pivoted at /a, the top roll is always in
contact with the delivery roll.
31. Operation of the Kolls.— In order that these rolls
may detach the combed cotton from the remainder of the
lap, they must be close enough to the fluted segment to
secure the cotton at the time of detaching. The position of
the rolls when detaching is shown in Fig. 16. By a compari-
son of this figure with Fig. 15, it is obvious that if, during
the combing operation, the detaching roll were in the position
that it occupies when detaching, the needles of the half lap
would come in contact with the detaching roll." It is there-
fore necessary that the position of the detaching roll should
be alternately changed so that the roll will be near enough
to the segment to secure the fibers when detaching and also
be out of the path of the needles during the combing action.
In order to effect this change in the position of the detaching
roll, it is necessary to give the shaft /,, Fig. 17, which is
primarily the support for the roll, a partial revolution. As
shown in Fig. 17, there extends from the short shaft /, an
arm k^, which, with other connections, serves to connect /,
with the shaft k. The connection between /, and k is
jointed at k^ and k,,; consequently, if /■ revolves it will
turn /, without tending to lift it in its bearings. There
are three of these connections for a comber of six heads,
there being one for each shaft /,. The shaft k is similar
to the shaft g^ shown in Fig. 12 and extends the entire
length of the heads. Fig. 9 shows the relative positions
of these shafts.
30 COMBERS §22
Extending from the shaft k is an arm X%, Fig. 17, which
carries at its other end a cam-bowl that runs in the course of
the lifter, or horsehead, camyi. This cam is on the shaft with,
and very close to, the nipper cam g^ shown in Fig. 12. As the
cam-shaft/ revolves, the shaft k receives an oscillating motion
that is transmitted to the shaft h by means of the connections
previously described. This motion of /, swings the horse-
head with /, as a center and thus brings the leather detaching
roll q in contact with the fluted segment, as shown in Fig. 16.
The range of movement of the horsehead is shown by the
full and dotted lines in Fig. 17. The full lines show the posi-
tion of the horsehead and rolls during the combing process, or
when the roll is out of the path of the half lap, while the dotted
lines show the position of the horsehead and rolls when the
detaching roll is in the position it assumes when in operation.
As previously stated, the detaching roll q is supported and
its motion governed through being held firmly against the
blocks L of the brackets /„ Fig. 17, by the weights q^.
Fig. 19. When, however, the horsehead is moved back to
the limit of its motion, shown by the dotted lines in Fig. 17,
the blocks h are so far back that they are not in contact with
the brass bushings of the detaching roll. The leather por-
tion of the roll, however, has a bearing directly on the fluted
segment, as shown in Fig, 16. As the weights q^, shown in
Fig. 19, are holding the detaching roll against the fluted
segment, it is obvious that the fringe of cotton will be effect-
ively gripped between them. The detaching roll is at all
times in contact with the delivery roll, around which it moves
with the action of the horsehead. As the top roll is connected
to the shaft /,, it also has a movement similar to the detach-
ing roll, and consequently moves around the delivery roll
and assumes the position shown in Fig. 16. A clearer t^.
Fig. 17, which is above the top roll and serves to keep it
clean, is also supported by the bearings that support the
top roll and has a motion similar to this roll.
32. In addition to the rolls being placed in the required
positions, they must also have a rotary motion in both
§22
COMBERS
31
directions in order to carry back a portion of the cotton pre-
viously combed, to which the detached portion must be con-
nected in order to deliver the cotton in a continuous line.
The mechanism by means of which the delivery roll derives a
motion in both directions is shown in Figs. 20,21, and 22.
This motion is also imparted, by means of frictional contact,
to the detaching- roll and top roll. The mechanism shown in
these figures consists of a cam s, situated on the cam-shaft J,
which also supports the nipper cam and the cam for placing
Fig. 20
the detaching roll in position. Running in the cam-course
of Si is a bowl s^ fastened at one end of a lever v, the lever
being pivoted on a shaft z', borne by the frame of the machine.
The other end of the lever has a pawl v^ hinged to it at zu,
which is connected to an auxiliary lever v^,; z-n also carries
a bowl V, in contact with a cam s^, which is in a position adjoin-
ing 5,. It wall be seen, therefore, that the action of the pawl z\
will be governed by the two cams Si, s^, through the levers v, v^.
The pawl v., is shown as being over the gear v^. It is held
in this position by an arm similar to v situated on the other
32
COMBERS
§22
side of the gear z\. This second arm does not have any
cam-bowl but, being connected to the other, forms a good
support for the pawl v^ that engages with the teeth of the
gear z\. The construction of the gear v^ is shown in Fig. 20.
This gear is fixed to the shaft 7',, on which z' is pivoted. On
the same shaft with the gear i\ is an annular gear lu enga-
ging with a gear on the delivery roll s, the relative position
of which with the cylinder o is shown in Fig. 20. The back-
ward and forward motions required of the delivery roll must
be imparted by the pawl v. through the gears z\, zu and the
gear on the delivery roll, the extent of the movement of the
delivery roll being governed by the movement of the gear z\
and the relative number of teeth in the gears by which the
delivery roll is driven.
33. The manner in which the pawl acts on the gear v^
may be seen by reference to Figs. 20, 21, and 22. The
pawl z'j is always tending to be drawn toward the gear zu by
two springs Vs, only one of which is shown. These springs,
however, cannot bring the pawl into connection with the
§22 COMBERS 33
gear until they are allowed to do so by the cam 5,. As the
cam-shaft revolves and the portion of the edge of the cam
that is nearest its center comes in contact with the bowl z',,
the pawl hinged at v^ will be drawn down by the springs until
it is in contact with one of the teeth of the gear v^.
The cam 5, will also be moving during this time in the
direction indicated by the arrow, and the bowl will come in
contact with that part of the cam nearest the center. This
position is shown in Fig. 21. Changing the position of the
Fig. -ll
cam from that shown in Fig. 20 to that shown in Fig. 21
results in moving the gear v^ in the direction shown by the
arrow. The delivery roll j- will receive a similar motion and
carry back a portion of the cotton previously combed.
The further rotation of the cam 5, will cause the cam-
bowl ^4 to be forced from the center j and this will cause the
pawl z'j, and consequently the gear zu, to move in an opposite
direction to that first described. The positions that these
parts assume during this motion are shown in Fig. 22. It is
therefore evident that the delivery roll v.'illhave two motions,
34 COMBERS §22
one of which returns a portion of cotton previously combed
while the other delivers the cotton that is detached. After
the latter movement has taken place, the cam s^ having moved
sufficiently far will remove the pawl from the gear zu. When
the pawl is next allowed to engage with the gear zu, it will
be in such a position that it will drop into the next tooth
beyond the one with which it previously engaged.
The delivering movement of the delivery roll is about
double its movement in the opposite direction, and the length
of cotton actually delivered is dependent on the amount that
the former exceeds the latter.
34. The operation of piecing-up may therefore be briefly
stated as follows: It is necessary to detach a combed fringe
of cotton from a lap and connect it to cotton already combed.
The combed fringe of cotton is supported by the fluted seg-
ment O3, as shown in Fig. 16. In order to connect this
fringe the cotton immediately in front of it is brought back,
by turning the delivery roll in the desired direction, and falls
in a space between the half lap and the fluted segment. After
the required amount of cotton has been returned, the detach-
ing roll is brought in contact with the fluted segment so that
it will grip the cotton to be detached. The delivery roll
is then revolved in the opposite direction to that by which it
returned the cotton previously combed, and at the same time
the detaching roll and the segment detach the cotton from
the layer brought forwards by the feed-rolls. During these
motions the forward ends of the fibers detached are placed
above and upon the rear ends of the fibers that were returned,
and thus they are joined together between the detaching roll q
and the delivery roll s, after which the detaching roll is moved
out of the path of the half lap so that it will not interfere
with the operation of combing the next tuft of cotton held
by the nippers.
COMBING BY THE TOP COMB
35. Another operation performed in connection with that
of detaching is the combing of that portion of the fibers
held by the nippers when the half lap is in action and
22
COMBERS
35
which, consequently, cannot be combed by the half lap.
This portion of cotton is combed by the action of the top
comb shown at the lower end of the plate ii. Fig. 23. This
comb is constructed with one or two rows of needles soldered
to the plate, it being claimed on the one hand that two rows
of needles give a more effective combing, while on the
other hand it is stated that dirt collects between the two
rows of needles and afterwards drops back into the cotton.
Another disadvantage of two rows of needles is that they
are more liable to come in contact with some of the moving
parts during the oper-
ation of piecing-up be-
cause of the small space
between the nippers and
the detaching roll. It
is also more difficult to
straighten the needles if
they become bent or
hooked than when a
single row is used.
When made with two
rows, there is usually a
coarse row with 30 teeth
per inch and a finer row
with 60 teeth per inch.
The plate, or blade,
to which the needles are
soldered is supported by
brackets z/,. Fig. 23, there being two for each comb, or
head. These brackets are connected to the shaft u^, which
extends the length of the heads and supports the brackets
for each head. At one end of this shaft is a lever ti^
carrying a cam-bowl Ut, which is in contact with the cam u«
on the cylinder shaft o». As the cylinder shaft revolves,
the top comb will be alternately raised and lowered by the
action of the cam. The comb is given this movement
because when the half lap is combing, as shown in Fig. 15,
the top comb must be up out of the way so that it will not
Fig. 23
36
COMBERS
§22
interfere with the action of the half lap. The top comb is
lowered immediately after the half lap has passed and before
the operation of detaching takes place. It is shown almost
in position in Fig. 24, where the half lap has just passed;
while in Fig. 16 it is shown in its combing position. As the
fibers are detached by the detaching roll and segment the
top comb is in its lowest position and the fibers that were
held by the nippers are drawn through the comb by the
detaching roll and segment; in this manner dirt and any
fibers too short to be held by the segment and detaching
roll are removed, after which the comb is raised so that it
will not interfere with the action of the half lap. The
matter combed out by the top comb that is not retained by
the fringe projecting from the feed-rolls drops into the
space on the cylinder between the fluted segment and the
half lap. The matter retained by the fringe is removed by
the half lap during its next combing operation.
22 COMBERS 37
DELIVERY OF THE STOCK
36. Calender Rolls. — The cotton when freed from the
action of the top roll and delivery roll is delivered into a
pan made of tin and shaped somewhat like a right triangle
with its base adjoining the delivery roll. A side 'view of one
of these pans is shown at w, Fig. 9. Each pan is from about
Ih inches to 2 inches deep, its bottom being perforated so
that any foreign substances that fall from the cotton will pass
out of the pan and thus be prevented from entering the
cotton again. At the end of the pan farthest from the deliv-
ery roll is a trumpet, as shown in Fig. 9, which has its larger
end in the pan. The cotton when delivered in the pan is in
the form of a transparent web nearly as wide as the leather
portion of the detaching roll. It is drawn through the
trumpet by the table calender rolls, which are shown at n
and «,, Fig. 9. By this means the web is condensed into the
form of a sliver and delivered on a table, as shown in Fig. 25.
37. The table and the table calender rolls for a
comber of six heads are shown in Fig. 25. The lower
calender rolls are on a shaft that extends the length of the
heads, while the upper ones, which are self-weighted, receive
motion by frictional contact with the lower rolls. These rolls
revolve continually at the required speed to take up the excess
amount of cotton delivered by the delivery roll over that
carried back for piecing-up, or in other words, the net amount
delivered by the delivery roll. As these rolls are revolving
continually in one direction, and as the delivery roll some-
times moves in the same direction and at other times in an
opposite direction, the web of cotton in the pan is alternately
slack and tight, which gives a wavy motion to the web. The
web at any time should not be so slack that it will fall to the bot-
tom of the pan, nor should it be so tight that it will be strained.
The table on which the slivers are delivered is about
7 inches wide. Its surface is polished in order to present
the least possible resistance to the slivers as they pass over
it. Guides are placed on this table at various distances from
^22
COMBERS
39
the calender rolls so that the different slivers will be guided
on the table and lie in a position side by side instead of
crowding on one another. In this manner, the slivers are
drawn along the table by the back rolls of a set situated in
tlie draw-box shown in Fig. 25.
38. The Dra^v-Box, — Up to this point each lap and the
sliver formed from each lap is treated individually. All the
slivers are, however, drawn into the clra\v-box together.
The draw-box has three pair of rolls, which may be either
of the common or metallic types, and these rolls give to the
sliver a slight draft, although the principal draft of a comber
is between the feed-rolls and the table calender rolls.
Fig. 26
39. The slivers after being subjected to the draft of the
drawing rolls are drawn through a trumpet by a pair of cal-
ender rolls and are thus condensed into one sliver. The
calender rolls that draw the slivers through the trumpet are
different in construction from most calender rolls; they are
shown in Fig. 26. The bottom roll ec has a groove into
which the small end of the trumpet projects, while the top
roll ?£',, which is driven by frictional contact, has a collar that
fits into the groove of the bottom roll. As the sliver runs
in the groove of the lower roll it will be effectively con-
densed by the top roll, which is self-weighted.
From these calender rolls the sliver passes to a coiler,
which is similar to the coilers described in connection with
other machines.
40 COMBERS §22'
SUMMARY
40. As the operation of a comber is somewhat compli-
cated, which is due to the many different mechanisms that are
brought into action, a short summary will be given here, as
an aid to the understanding of the operations as a w^hole.
In order to bring the cotton into a position to be combed,
it is first necessary that a certain length should be delivered
by the feed-rolls. After the cotton has been fed by these
rolls, the nipper knife descends and not only grips it firmly
but also, by depressing the cushion plate, brings the fringe
of cotton into a suitable position to be acted on by the
needles of the half lap. The cylinder is in such a position
that, when the nipper knife has completed its downward
motion, the first row of needles on the half lap enters the end
of the fringe of cotton, and, as the cylinder revolves, the
successive rows of needles remove all the fibers that are too
short to be retained by the nippers, as well as the neps that
have been left in the cotton. After the needles on the half
lap have passed the fringe of cotton, the ends of the fibers
fall into the gap left between the needles and the segment,
and the nipper knife, together with the cushion plate, begins
to rise. When the cushion plate has reached its uppermost
position, the further lifting of the nipper knife releases the
fibers at this point. During this operation the portion of the
cotton previously combed has been brought back and is now
ready to be pieced up with the cotton that has just undergone
the combing operation by the half lap.
The cylinder having revolved until the fluted segment is
in the desired position, the detaching roll descends and grips
the cotton firmly between itself and the fluted segment. The
further revolving of the fluted segment, together with the
detaching roll, draws away the fibers that are not held by
the grip of the feed-rolls, and since the top comb has by
this time dropped into such a position that it protrudes into
the end of the lap just in advance of the portion that has not
been cleaned by the needles of the half lap, it efficiently
combs this portion of the fibers. At the beginning of this
§22 COMBERS 41
operation the forward ends of the fibers being combed are car-
ried forwards sufficiently to overlap the r^ar ends of the fibers
that were returned; consequently, the forward rotation of the
delivery roll, which occurs while the detaching roll is in contact
with the segment, assists in piecing up the fibers just detached
to those previously combed, and delivers them into the pan.
It should be clearly understood at this point that all the
fibers do not project from the feed-rolls to the same extent
at one time. For example, some of the fibers may not be
gripped by the feed-rolls at all, while other fibers may pro-
ject beyond the feed-rolls a quarter of their length, some
half of their length, and some three-quarters of their length;
consequently, when the detaching action takes place, only
those fibers that project entirely beyond the feed-rolls are
gripped and drawn forwards by the action of the detaching
roll and fluted segment, while those fibers that project
only partly beyond and are still gripped by the feed-rolls
form a fringe of cotton that is always present in front of
the feed-rolls. At the next delivery of the feed-rolls those
fibers that previously projected only partly beyond the rolls
may now project entirely beyond the rolls, and consequently
at the next detaching operation these fibers will be drawn
forwards in a manner similar to those previously detached.
From the delivery roll, the cotton passes into the pan,
through the trumpet, between the table calender rolls, and
is delivered on to the table, along which it is drawn together
with the other slivers that have been delivered by the various
heads. From the table the slivers pass to the draw-box,
where they are given a slight draft, after which they pass
through a trumpet and between a pair of calender rolls,
where they are condensed into one sliver. From the calen-
der rolls the sliver passes to the coiler and then to the can.
GEARING
41. A plan of the gearing of a comber is shown in
Fig. 27. and from this figure the manner in which the vari-
ous mechanisms receive their motions may be seen. The
42 COMBERS §22
pulley 5-, is driven from the shafting of the room. This
pulley is firmly keyed to the short shaft z, which is carried
by the framing and steadied in its motion by the balance
wheel z„ in order to prevent a variation of speed, which
might be caused by the intermittent actions of some of the
parts of the comber.
On the shaft z is fixed a pinion of 21 teeth, which drives
a gear of 80 teeth on the cylinder shaft o^. Meshing with
the gear of 80 teeth on the cylinder shaft is a gear of 80 teeth
on the cam-shaft j; consequently, the cam-shaft and cylinder
shaft revolve at the same speed. On the cam-shaft, the
positions of the various cams are shown, these being the
nipper cam g^, the cam 7, for placing the detaching roll in its
required position, and the cams ^i, s^, Fig. 20, these two
latter cams being situated at the extreme right of the cam-
shaft in Fig. 27. The shaft supporting the lower table cal-
ender rolls is driven from the cam-shaft as shown.
Combers were first constructed with a short cam-shaft, and
the cams were placed nearer the driving end of the machine.
The connections to the shafts from which the nippers receive
motion and from which the detaching roll is placed in posi-
tion were at one end of these shafts. When constructed in
this manner, the torsion on the shafts was such that the
parts for each head that received motion from these shafts
did not work simultaneously. The first remedy was to make
the shafts larger, but later the combers were constructed
with the nipper and lifter cams in the center of the comber,
so that the connection was made to the centers of the shafts
that they operated.
The disk containing the pin from which the feed-roll
receives motion, as shown in Fig. 10, is attached to the gear
of 80 teeth on the cylinder shaft. The star gear c^ of 5 teeth,
shown in Fig. 27, is on a short shaft, the other end of which
carries the draft change gear fe, which drives a gear c-, on
the feed-roll. At the other end of the feed-roll is a gear
that, by means of the shaft x, drives the lap rolls a,a^.
The brush p, which cleans the needles of the half lap used
in the combing process, is driven from the shaft z through
44 COMBERS §22
a carrier gear, change gears being provided for driving the
brush shaft at different speeds. The cylinder shaft at its
end opposite to that of the gear of 80 teeth has a gear that
drives the doffer by means of the shaft ra, and also the
drawing rolls of the draw-box and the calender rolls by
means of the shaft u\. From this end of the cylinder shaft,
the coiler is driven by the gear of 60 teeth, change gears
being provided so that the speed of the coiler may be altered
in order to have the coiler properly take up the sliver. The
comb for removing the waste from the doffer is not shown
in the figure, but it is driven by a simple crank-motion, the
stud that turns the crank being at the extreme inner end of
the shaft 2.
42. The draft for the gearing shown in Fig. 27, with an
18-tooth draft change gear, figuring from the 2-inch coiler
calender roll to the 2f-inch lap roll at the back of the comber,
is as follows:
2 X 16 X 16 X 60 X 5 X 38 X 22 X 55 X 47 _ 23 579
16 X 16 X 69 X 1 X 18 X 23 X 20 X 35 X 21
As the comber removes a very large percentage of waste
from the cotton that passes through it, it is not possible to
figure accurately the weight of the sliver produced by simply
taking into consideration the weight per yard of the lap fed
in, the number of doublings, and the draft of the machine.
An example will make this point clearer.
Example. — Suppose that a comber with a draft of 23.579 has six
laps up at the back, each lap weighing 260 grains per yard, and it is
desired to find the weight per yard of the sliver delivered.
Solution. — Multiplying the weight per yard of the laps fed in by
the number of laps, and dividing by the draft gives 66.1605 grains as
the weight per yard of the sliver delivered; " ,^ = 66.1605. If 20 per
cent, of the cotton that passes through the machine is taken out as
waste, the result obtained above must be diminished by 20 per cent.,
in order to obtain the actual weight per yard of the sliver delivered;
20 per cent, of 66.1605 is 13.2321, which deducted from 66.1605 gives
52.9284 as the grains per yard of the sliver produced. Ans.
J
§22
COMBERS
45
VARIATIONS IN CONSTRUCTION
43. Quadrant Motion. — A different mechanism for
imparting the rotary motions to the delivery roll is shown in
Figs. 28, 29, and 30, and is applied to combers that have their
other parts constructed in a manner similar to those described.
This mechanism consists of a cam s, known as the
giiadra7it cam, which is fast on the cam-shaft/. Working in
46
COMBERS
§22
Fig. 29
lever v^ that is centered at v-.
the cam-course is a bowl s^ that is supported by the lever s,
centered at s^. The other end of this lever contains teeth,
and it is from the shape of the lever that the name quadrant is
derived. The toothed por-
tion St, Fig. 30, of the lever ^,
connects with a gear 5e loose
on the delivery roll s. At one
end of the gear ^e is one part
of a clutch that, when brought
in contact with the other
part s^ that is fast to the
delivery roll s, will impart
any motion of the gear s^ to
the delivery roll. The cam Vi,
Fig. 30, which is also on the
cam-shaft, by means of the
moves the part of the clutch
that is loose on the delivery roll into, and out of, contact with
the other part. It will be seen
that with this construction the
delivery roll will receive motion
from the cam s^ during the time
that the parts of the clutch are
held in contact by the cam i',.
When in action, the clutch is first
connected by means of the cam z-',
acting on the lever v.,, Fig. 30,
the clutch corresponding to the
pawl Vi in the mechanism pre-
viously described.
The delivery roll then begins
to turn back as the bowl of the
cam 5, leaves the line o, Fig. 29,
and approaches the line o^. At
the line o^, the cam-bowl com-
mences to move from the center of the cam-shaft, thus
reversing the motion of the delivery roll. This reverse
motion ceases when the clutch is disconnected by means of
Fig. 30
§22 COMBERS 47
the cam i\, Fig. 30, which occurs at the time that the cam-
bowl Js is about to enter that part of the cam-course that is
nearly concentric with the cam-shaft. The points at which the
clutch is connected and disconnected will govern the character
of the piecing in the same manner as the action of the pawl
described in connection with Figs. 20, 21, and 22,
44. Another method of lifting the leather detaching roll
is shown in Fig. 28. On the lifter shaft k is an arm k^ that
carries a stud on which works loosely a square block k„; on
the shaft / is an arm X^, on the lower end of which is a cut-
out into which the square block k. fits. As the arm k^ is
moved by the action of the lifter cam, it, in turn, moves the
arm k:, and shaft / and so lifts and lowers the leather detach-
ing rolls. One point of improvement claimed for this method
is that there is less lost motion^ and therefore a more accurate
setting of the leather detaching roll is obtained.
Another method of lifting the leather detaching roll is to
connect the shafts / directly to the lifter cams, using a sepa-
rate cam for each shaft, w^hich usually operates the rolls for
two heads.
DOUBLE-NIP COMBER
45. Purpose. — In order to obtain a greater production
than is obtained with a comber constructed as previously
described, machines known as double-nip combers are
built. These combers act on two portions of cotton during
each revolution of the cylinder, whereas in a single-nip
comber only one portion of cotton is treated for every revo-
lution of the cylinder.
46. Construction. — The cylinder of a double-nip
comber contains two half laps and two fluted segments, but
the half laps have only thirteen rows of needles in place of
the seventeen of the single-nip comber, since two half laps of
seventeen rows each would occupy too much space. The
segments are also made correspondingly narrower. The seg-
ments and the half laps are arranged alternately on the cylin-
der with shght spaces between them, in order that the cotton
48 COMBERS §22
may assume the positions shown in Fig. 16 and thus be
properly pieced up. A sectional view of a double-nip comber
equipped with a clutch and quadrant is shown in Fig. 28.
In order that a portion of cotton shall be presented to each
half lap, or that the feed-rolls shall receive motion twice for
every revolution of the cylinder, another pin is placed on the
disk plate, shown in Fig. 10, in such a position that the two
pins will be exactly opposite each other. The other inter-
mittent motions of the machine must therefore have two
movements for each revolution of the cylinder shaft; this is
provided for by having the gearing arranged in such a manner
that the cam-shaft receives two revolutions for every revolu-
tion of the cylinder shaft, thus causing the parts that receive
their movement from the cams on the cam-shaft to perform
their work twice during this time.
47. A comber with a double nip gives a greater produc-
tion than a comber with a single nip, but does not, however,
clean the cotton so well, because of the smaller number of
needles acting on the fringe. Another disadvantage of the
double-nip comber as compared with the single-nip comber is
due to some of the parts running at such a high speed that
they not only wear out more quickly but easily get away
from their proper settings and timings, thus producing
bad work.
COMBERS
(PART 2)
SETTING AND TIMING
INTRODUCTION
1. Aside from the general construction of a comber, two
subjects closely related to the machine and very important to
the success of the combing process that should be considered
in this connection are setting and timi7ig. The setting of a
comber implies regulating the distance between its working
parts by gauges. Timing is a process that has arisen from
the fact that a comber is intermittent in its action and that
it is therefore necessary to time the motions of its various
parts so that they will be performing their work when some
working part that is taken as a basis for timing is perform-
ing a certain operation.
Although the range within which these settings and timings
can be regulated and worked successfully is very limited, it is
very seldom that two persons in charge of combers will agree
on these questions. The principal points to be taken into
consideration, however, are the length of the staple of the
cotton to be used, the weight of the lap fed, the kind of cotton
used, the quality of the work required, and, as a consequence
of the last, the amount of waste to be combed out.
It is obvious that a different combination of settings and
timings will be required when cotton with li-inch staple is
being used than when the cotton has a If-inch staple. This
is also true in connection with medium or low grades of
combed yarn as compared with fine yarns, since it is not nec-
essary to take out so much waste in the former case.
For notice of copyright, see page immediately following the title page
?23
COMBERS
§23
SETTING
2. Gauges. — The several kinds of gauges used in setting
a comber are shown in Fig. 1, and include the regular comber
gauge (a), the step gauge {d), the finger gauge (c) , the
quadrant gauge (d) , the cradle gauge {e) , and brush gauge (/) .
1. Cofuber Gauge. — There are several gauges similar to
a, the blades of which vary from No. 12 to No. 28 in thick-
ness. They are numbered according to a wire gauge and
decrease in thickness as the numbers increase, a No. 20
X
1^
(^)
(a)
X
i^
:a
^
(f)
Fig. 1
meaning that the gauge is equal in thickness to a No. 20
wire. These gauges are about f inch wide, and usually
about 4^ inches long. Each really consists of two gauges,
one at each end; for example, the one shown in Fig. 1 {a)
has a No. 20 gauge at one end and a No. 21 gauge at the
other end. For settings finer than a No. 23 gauge, strips of
paper are sometimes used, although this method is not as
reliable as the use of the regular gauges.
2. The step gauge {b) is composed of one piece with steps,
each step being iV inch thicker than the preceding one. The
i
23
COMBERS
first step is generally i inch in thickness. The width of this
gauge is about i inch.
3. The finger gauge (c) is measured from the arrowhead
on the curved portion to the arrowhead on the straight end
and varies from Is inches to 2 inches in length; it is about
-1% inch in thickness.
4. The quadrant (d) is used for determining the angles
of top combs.
5. The cradle gauge {e) is used to hold the top comb in
position while it is being fastened to the comb arms.
6. The brush gauge (/) is used for setting the brush shaft
parallel to, and at the required distance from, the cylinder
shaft.
Assuming that a comber has merely been set up and that
the cylinders are loose on the cylinder shaft, the parts that
require setting with gauges and the gauges used for making
each setting are given in Table I.
TABLE I
Parts to be Set
Delivery roll from segment
Front flute of segment from delivery
roll
Feed-roll from delivery roll
Cushion plate to nipper knife ....
Distance of setscrew /a from stand
when d is down, Fig. 3
Cushion plate from delivery roll . .
Distance of nipper from half lap
when nipper is in its lowest position
Brush to half lap
Top comb set at angle of from
25° to 30°
Top comb from fluted segment . . .
Distance of blocks A, Fig. 8, from
bearings of detaching roll when
resting on segment
Top roll from leather detaching roll .
Gauge
Comber
Finger
Finger
With paper
Step
Finger
Comber
Brush
Quadrant
Comber
Size of Gauge
No. 23
\\ inches
According to staple
i to f inch
According to staple
No. 20
No. 20 or 21
Comber I No. 23
Comber I No. 21
4 COMBERS §23
3. Setting the Various Parts. — 1. In making any set-
ting in any machine, some one point, usually a shaft, is taken
as a basis. In the comber, the cylinder shaft is primarily the
base of all settings, from the fact that the cylinder, which is
used to set from for certain settings, is centered on that shaft;
but as the delivery roll is a more convenient point from
which to work when making certain of the settings, it is
given a true and accurate setting with a certain definite
relation to the cylinder, and after being certain that it will
revolve freely in its bearings, these bearings are secured,
and the delivery roll becomes the base of certain of the set-
tings of the comber.
The cylinder shaft and delivery roll of the comber revolve
in bearings that do not have any motion during the various
operations of the comber, and which after the first setting
have a definite relation to each other as to distance. The
fact that the cylinder can be moved on the cylinder shaft
does not affect the distance between the faces of the segment,
or the half lap of the cylinder, and the face of the delivery
roll.
In order to have the cylinder and delivery roll in their
proper relative positions, it is first necessary to line up the
delivery roll, which is done by presenting each fluted segment
of the comber to the delivery roll and moving the bearings
of the delivery roll until the space between the surface of this
roll and the surface of each fluted segment is equal to a
No. 23 comber gauge. The distance should be tested at
both ends of each segment. When this has been done, the
cylinder shaft and all parts carried on the cylinder shaft have
a definite relation as to distance from the delivery roll, and
although certain settings are made from either base, they
do not conflict with one another.
2. Front Flnte of Segment From Delivery Roll. — After
setting the delivery roll and being positive that it revolves
very freely in its bearings, the index gear (which will be
described later) should be placed at 5, after which the cylin-
ders are fastened on the cylinder shaft. One cylinder is
first secured so that the front edge of its fluted segment
§23 COMBERS 5
approaches within a certain distance of the face of the delivery
roll, after which each of the other cylinders of the comber
is set with its fluted segment the same distance away.
When this has been done, the first flutes of all the seg-
ments across the comber will be in one straight line. A
finger gauge li inches long may be used, but care should
be taken in making this setting that the position of each
segment is accurate, since the perfect alinement of these
parts is vital to the quality of the product.
When making this setting, the curved face of the finger
gauge is placed on the flutes of the delivery roll and the
cylinder turned on its shaft until the front part of the seg-
ment comes in contact with the opposite face of the gauge.
The space between these two parts should first be tested at
one end of the segment, and when this end is in its correct
position the cylinder is secured by means of a setscrew to
the shaft at this end, after which the gauge is passed along
the length of the segment to make sure that it is the correct
distance at all points from the delivery roll; the cylinder is
then fastened at its other end by means of a setscrew. The
same method is adopted with each of the other cylinders,
care also being taken to have all the cylinders exactly in the
centers of the heads.
3. Feed-Roll Fro^n Delivery Roll. — Setting the feed-roll
from the delivery roll is accomplished by moving the bear-
ings of the feed-roll. This is a very important setting, since
if these rolls are not exactly parallel, there will be a strain
on the fibers at one side and only a partial detachment of the
fibers on the other side during the operation of detaching.
The feed-roll must also be parallel to the cylinder, otherwise
one side of the lap will be combed more than the other. If
any of these faults exist, a cloudy and uneven web will be
produced. The finger gauge is used for this setting; its
curved face should be on the flutes of the delivery roll, while
the opposite face should be in contact with the flutes of the
feed-roll, but these rolls should not be set so close that the
gauge cannot have an easy upward movement. The distance
should be tested at both ends of each fluted section.
COMBERS
§23
This setting of the feed-roll varies according to the staple
and nature of the stock, as shown in Table II.
TABLE II
Cotton
Length of Staple
Inches
Size of Gauge
Inches
American
Egyptian .......
Egyptian and sea-island
About IT
Up to li
1 2 and longer
IT6 to IT6^
itI to lH
ItI to 2
4. Cushion Plate to Nipper Kiiife. — Before setting the nip-
pers, the cushion plate must be adjusted so that the nipper
knife, when down, will be in contact with the cushion plate
at an even pressure throughout its entire width. If it does
not touch along its entire edge, the fibers will be held tightly
at one side, while on the other side they will be held loosely.
The cotton that is not held securely by the nippers will be
pulled out by the half lap and eventually arrive at the waste
can, causing a waste of good cotton.
The efficiency of the half lap also depends on this setting.
Care must also be taken that the nose, or front edge, of the
cushion plate is evenly and properly covered, in order that it
may present a perfectly even surface along its entire length.
In setting the parts, two strips of ordinary writing paper,
one at each end of the knife, should be placed between the
front part of the cushion plate and the overhanging lip of the
nipper knife, and the setting between these parts made as
close as possible and yet allow the two strips to be easily
drawn from between the lip of the knife and the round nose
of the cushion when the knife is in contact with the cushion
plate. The same test is then made in the center and between
the ends and the center. The fluted edge of the knife should
be set so that a narrow strip of paper will be held firmly
between the cushion plate and the nipper knife when the
knife is pressed down on the cushion plate.
Setting the cushion plate to the nipper knife is performed
by loosening three screws similar to Jk, Fig. 2, and moving the
23
COMBERS
plate to the knife by screws similar to h^. After the proper
setting has been secured, the screws //., are screwed as tightly
as possible.
5. Distance of Setscrew From Stami. — Before the cushion
plates are set to the delivery roll, the setscrew z,. Fig. 3,
should be adjusted. In making this setting, it is a good
plan to have the screw project through the arm i^ so that
when it is resting against the stand /, the arm i^ will be
in a perpendicular position. This can be accomplished by
holding a level on the front face of the arm i. and turning
Lx^
Fig. 2
the screw ?3 until the arm i^ is in the required position.
This should be done at each head. The only object of this
setting is to have each head set alike and thus have some
definite basis to work from when making future settings.
6. Cushiofi Plate From Delivery Roll. — It is now necessary
to set the cushion plates the desired distance from the delivery
roll. The position of the cushion plates with relation to the
portion / and the nipper knife has been determined and must
not be disturbed; therefore, in order to adjust any one of the
cushion plates to the delivery roll, the whole nipper mecha-
nism must be moved. In making the setting between the
COMBERS
23
cushion plate and the delivery roll two operations are
employed. In the first case a general setting is made by
loosening the bolts (not shown in Fig. 3) that attach the
^^rrr]
Fig. 3
nipper-mechanism stands / to the framework, and moving
this mechanism on the framework nearer to, or farther from,
the delivery roll until the cushion plate is exactly the same
distance from the delivery roll at each end, which insures
§23
COMBERS
the delivery roll and the nose of the cushion plate being
parallel. Afterwards a more accurate setting is made by
means of the setscrews 2\.
The entire operation is as follows: After loosening the
'bolts that attach the nipper-mechanism stands / to the frame-
work, the finger gauge is placed with its curved face on the
delivery roll and the nipper mechanism moved forwards
until the round nose of the cushion plate is against the
straight face of the gauge. This distance is tested at each
end of the cushion plate and at intervals between. When
the cushion plate has been set parallel to the delivery roll, the
nipper mechanism is tightly secured on its seat by means of
the bolts. Next, the gauge is again inserted at each end
of the cushion plate and at intervals along the plate, and
by means of the setscrew i^ the setting is made so close
that the gauge cannot have an easy vertical movement.
As the bracket i that carries the arm /^ swings on the
center i^, the effect that is produced on the nipper mechanism
by moving the setscrew i^ can readily be seen. The settings
of the cushion plate are governed by the length of the staple,
the class of cotton, and the weight of the lap used. General
settings for this part of the comber are given in Table III.
TABI.E III
Cotton
Length of Staple
Inches
Size of Gauge
Inches
American ....
Egyptian
Sea-island ....
li
li to IT
Over li
li to lA
11% to IT
IT to 11^6
7. Distance of Nipper From Half Lap Wheji Nipper is in
Its Loivest Position. — The setting of the nipper to the half lap
is performed by the sliding bracket /., Fig. 3, and setscrew /..
The bolt holding the sliding bracket /, should be loosened
and a step gauge placed between the end of the setscrew /,
and stand /. The object of inserting a step gauge at this
10 COMBERS • §23
place is to swing the nipper mechanism on the center /^ until
the nipper knife is in exactly the same position that it
assumes when the cotton is being combed by the needles on
the half lap. A step gauge must therefore be selected that
gives the exact throw to bring the nipper knife into the
required position. During this setting, however, the nipper
knife is pressed down on the cushion plate and the lip d^
projects beyond this plate. The setting is made by inserting
a No. 20 comber gauge, Fig. 1 {a), between the edge of the
nipper knife and the needles of the half lap. The cylinder
shaft should be turned so that the points of the needles
come directly under the edge of the nipper knife. Each end
of the nipper is then accurately adjusted by either raising or
lowering it by means of the setscrews A. The cylinder
shaft should then be turned and the gauge inserted between
each row of needles and the nipper knife.
When the setting is completed, it should be possible to
move the gauge the entire width of the nipper without too
much resistance. In passing the gauge between the nipper
knife and the needles, it is a good plan to slide the gauge on
the edge of the knife, that being a smooth surface. When
this setting has been completed, the bolts that hold the
sliding brackets A to the stands / should be tightened. The
springs z's should next be put on and adjusted to the proper
tension. This may be done by the nuts on the spring screw.
This method of setting is of course adopted at each head on
the comber.
8. Setting the Top Comb. — One of the top combs should
next be set at an angle of from 25° to 30°. When making
this setting, the detaching roll should be on the fluted seg-
ment in position to detach, and particular care taken to have
the top comb set so that it will not come in contact with the
nippers or leather detaching roll. The brackets ti^. Fig. 4,
should be loose on the shaft u^ so that they will allow the
adjustment of the comb. The screws holding the comb to
the brackets //, should also be loose. The quadrant gauge
is used in making this setting, it being so constructed that
its lower part fits over the blade of the comb, to which it
23
COMBERS
11
is secured by a thumbscrew. The comb is so set that the
plumb-bob on the gauge will fall in a position to give the
correct angle, which can be learned from the scale on the
gauge. When the top comb is at the correct angle and
not in contact with either the nippers or leather detaching
roll, the screws that fasten the comb at each end to the
brackets id, Fig. 4, should be secured.
After one comb has been placed in position with the use
of the quadrant gauge, the remaining top combs to be set
are in some cases placed in position by what is known as a
cradle, Fig. 1 (^), which
consists of a casting
having two bearing
points for the comb to
rest on and two set-
screws that bear against
the blade of the comb.
By moving these set-
screws, the comb may
be held at any desired
angle. Having set one
comb, the cradle is set
on the fluted segment,
the base of the cradle
being curved to con-
form to the curvature of
the segment. The top
comb, which has been
set by the quadrant gauge, is then lowered on to the cradle
and the screws of the cradle regulated so that they just bear
against the blade of the comb. After having regulated
the screws of the cradle, it is merely necessary, when it is
desired to set another top comb, to place it in the cradle
and then place the cradle on the fluted segment and secure
the comb to the brackets ?^, Fig. 4, while the comb is held in
position, after which the cradle is removed.
The quadrant gauge of course could be used for each
head, but it saves time and is sufficiently accurate to use the
Fig. 4
12 COMBERS §23
cradle gauge after the top comb of the first head has been set,
especially when a large number of combers have to be set.
9. Top Comb From Fluted Segme?it. — When the top comb
has been set to the proper angle, the distance between it
and the fluted segment is regulated by means of the
screws Wa, Fig. 4. A No. 20 gauge may be used and the
comb adjusted so that the gauge will pass between it and the
fluted segment without too much resistance. In passing
the gauge between the top comb and fluted segment, it is a
good plan to slide the gauge on the fluted segment and drop
the comb so that the points of the needles can be felt as the
gauge passes under them. The same method of setting the
top comb is then employed at each head of the comber.
When the top combs have all been set the proper distance
from the fluted segment, the brackets tc^ should be secured
to the shaft ii^ and the screws u^ adjusted. To accomplish
this, the cam u^ on the cylinder shaft is turned so that the
bowl «7 will be on the part of the cam nearest the center. A
gauge about the thickness of a No. 18 comber gauge is
placed between the bowl and the cam, and the brackets ««
secured to the shaft u^ while it is held in this position. The
setscrews iis should now be set so that a piece of paper can
be drawn between the ends of the screws and the projections
on the brackets u^. These screws should be adjusted so that
the paper will be drawn out at an even tension at each head.
Care should be taken while this is being done that the
screws u, are resting on the stands /. After all these brackets
have been set, the gauge should be removed and the lever tie
raised by hand; by watching carefully, it may then be ascer-
tained whether or not the top combs move exactly together.
The last two settings mentioned in Table I are more readily
made after certain of the timings have been made, and will
be described later.
MINOR SETTINGS
4. Adjusting the Nipper Rods. — The connections
may now be made between the nipper cam and the brackets e,
Fig. 3, that operate the nipper knife. To accomplish this,
§23
COMBERS
13
disconnect the cam-shaft from the cylinder shaft by sliding
the gear on the cam-shaft out of gear with the one on the
cylinder shaft with which it meshes. The cam-shaft should
then be turned until the cam-bowl operated by the nipper
cam ^., Fig. 5, is in the position that it should occupy when
the cushion plate is at its lowest position; that is, the
cam-bowl will be at the toe of the cam, or the point farthest
14 COMBERS §23
from the center of the cam, as shown in full lines, Fig. 5.
When the cam-bowl is in this position, place the step
gauge between the end of the setscrews i\ and the stands /,
Fig. 3, and connect the rod g, Fig. 5, to the bracket g^
and nipper bracket e, Fig. 3, commencing with the rod
nearest the driving end of the machine and setting that
rod in each head. These rods should be so adjusted by
the nuts at the bottom of the rods that the step gauge
may be moved between the stand and the screw /'a with-
out a great amount of resistance. When this has been
accomplished, the other rods of each head similar to g may
be connected and adjusted in like manner. After this is
done, the step gauge should pass between the ends of all
the screws /a and the stands / with the same resistance.
The step on the step gauge to be used between / and /a
depends on the distance that the cushion plate has to be
depressed in order to bring it in the proper position for
combing; a i-inch or f-inch gauge is generally used.
The cam-shaft and cylinder shaft may now be connected.
Before this is done these two shafts should be placed in
their correct relative positions. First, the cam-shaft should
be in the same position that it occupied in making the
previous setting; that is, the cam-bowl on the nipper cam
should be in a position farthest from the center of the
cam. Next, the cylinder shaft should be turned so that
the pointer will stand at 17 on the index gear. The gear on
the cam-shaft may then be placed in gear with the gear
on the cylinder shaft and secured by bolting it to the flange
of the sleeve on the cam-shaft.
5. The Revolvina: Brush. — The revolving brush p,
Fig. 6, that cleans the needles on the half lap should be set
so that the ends of the bristles will just touch the brass bars
that hold the needles. This setting is governed by the extent
to which the brush cleans the needles. If it is noticed that
waste remains on the half lap after the needles have been
brushed, the brush should be set closer, although no attempt
should be made to set the brush so near to the half lap that
— , .j —
V::«'5r
o
§23 COxMBERS 15
those small portions of cotton that become wedged in the
spaces between the bars holding the needles will be removed,
since these small portions are held so firmly that it is usually
necessary to pick them out with a piece of sheet metal.
The bearings of the brush shaft are held in slides in upright
supports, and when it is desired to set the brushes the nuts
that hold the bearings of the brush shaft are loosened and
the position of this shaft regulated by screws similar to the
screw pi, Fig. 6. These screws are connected to the brackets
that support the brush shaft and their heads are in contact
with projections on the framing. An adjustable gauge some-
times used for setting the brush shaft is shown in Fig. 1 (/),
and is composed of two parts, one having a slot through
which a bolt passes, thus allowing the gauge to be made
longer or shorter and held at any desired length by the bolt.
One part of the gauge has a curved face similar to the finger
gauge, while the other part is brought to a point at one end.
When it is desired to set the brush shaft closer, the gauge is
set so that the length from the center of the curve to the point
is slightly less than the distance between the circumferences
of the brush shaft and cylinder shaft. The curved face of
the gauge is then placed on the brush shaft and this shaft
moved nearer the cylinder shaft until the point of the gauge
comes in contact with the latter. The gauge should be
tried at both sides of every head. The brushes of the heads
are all on one shaft, and consequently in setting them care
should be taken not to set one so much out of line with the
others that the shaft will bind in its bearings.
6. Tlie Doffer. — The doffer r. Fig. 6, which receives the
waste cotton from the brush, should be set about iV inch
from the brush. The bearings of the doffer shaft are moved
by means of screws similar to the one shown at r,. Fig. 6.
The doffers for all of the heads are carried on one shaft,
and in setting them care must be taken to see that this shaft
can revolve freely in its bearings. The bearings of the
doffer-comb shaft are attached to the bearings of the doffer
shaft, so that the relative positions of the doffer and doffer
16 COMBERS §23
comb are not changed when the dofifer shaft is set closer to
the brush shaft. Adjustments are provided, however, for
setting the doffer comb to the doffer by having slots in the
brackets that support the comb. The comb should be set
about iV inch from the doffer at the lowest point of its
stroke and at an angle of about 30° from the perpendicular
at the upper part of its stroke.
7. Top Feed-Roll. — The top feed-roll is now placed in
position and adjusted so that it will be parallel with the
bottom feed-roll and in such a position that the ends of the
arms c^. Fig. 6, will not come in contact with the ends
of the nipper bracket. The adjustment is made by moving
the stud on which the arms c, are pivoted. The springs f,
should now be put on and adjusted so that the tension will be
equal on both ends of the roller.
The tins that cover the brushes and cylinders should be set
square and true and in such a position that they will not be
in contact with the cylinders, brushes, or doffers. The lap
apron should be placed in position and adjusted so that it is
level and true and exactly in the center of the head. The
brush for cleaning the feed-roll, which is adjustable on the
lap apron, should be so set that the ends of the bristles will
just touch the flutes of the bottom feed-roll.
8. Sliver Pans. — The sliver pans should be placed in
position and adjusted so that they set squarely on the shaft A,
Fig. 6, and so that the trumpets are in their proper positions
relative to the calender rolls.
9. Draw-Box. — The rolls of the draw-box should be set
the proper distances from center to center according to the
staple being run. The description of other settings will be
better understood after the timing of certain parts has been
considered, and therefore will be given kiter.
I
23 COMBERS 17
TIMING
10. After all the parts are set, the cams must be adjusted
so that they will operate the different motions, or place in posi-
tion the different parts that they control, at exactly the right
moment when they are required to perform their work. In
order to regulate this timing and indicate the time when each
operation should be set in motion or each part in position, it
is necessary to take some revolving part of the comber as a
basis from which to work and to time all parts in relation to it.
The cylinder is taken as a basis, as all the intermittent move-
ments of the comber are completed within the time occupied
by one revolution of the cylinder. It is furthermore neces-
sary to have some means of indicating in what position the
cylinder should be when each individual motion takes place
or each individual part arrives in its proper position.
For this purpose, a gear of 80 teeth, on the cylinder
shaft, is divided into twenty equal parts, or sections, which
are numbered on the rim of the gear from 1 to 20, each
section containing 4 teeth. This gear is known as the
index gear. A vertical index finger is placed on a station-
ary part of the comber directly over the cylinder shaft,
pointing upwards, and indicates by its relation to the posi-
tion of the index gear the position of the cylinder.
The numbers are so placed that as the cylinder revolves,
No. 1 is first brought opposite the index finger, then No. 2,
No. 3, and so on up to 20. Each section of the index
gear is spoken of as a whole number, and each tooth in a
section is spoken of as i; that is, if the cylinder has revolved
until the comber is said to be at 51, it indicates that the
index finger is at the second tooth beyond the section
marked 5 on the index gear, or 22 teeth from the section
marked 20. It is sometimes the custom in a mill to read
as a clock is read, the position of the gear with reference
to the index finger; thus, the above timing would be read as
half-past five. If the index is at 7, or if it is said to be
7 o'clock, it means that the cylinder has been revolved until
seven sections, or 28 teeth, have passed the index finger.
18 COMBERS §23
From this description it will be seen that if the motions of
a comber are listed according to their precedence and the
timing of each indicated according to the position of the
index gear with relation to the index finger, the timing will
be indicated by continually increasing numbers, and a com-
parison of the timings will show at a glance the relation
between the different motions and the relative time that will
elapse between them.
The actions to be timed are: (1) The motion of the feed-
rolls; (2) the motion of the nippers; (3) the placing of
the detaching roll and top roll in position for detaching;
(4) removal of detaching roll from detaching position; (5)
motions of the delivery roll; (6) movement of the top comb.
11. Timing the Feed. — The time when the feeding
begins to take place varies from 41 to 6, owing to the fact
that more waste is taken out of some cottons than others,
and the later the feed the more waste is taken out. When
combing Egyptian cotton, the feeding is done comparatively
early, as the fibers of this cotton do not vary much from the
average length, thus requiring the least waste to be removed;
consequently, this cotton is the easiest to comb. The fibers
of the sea-island cotton vary from the average length more
than the fibers of other cottons that are combed, so that sea-
island is fed late; Peelers and other American cottons occupy
about a central position between these extremes.
When timing tlie feed the cylinder is turned to the
desired position and the pin c^, Fig. 7, so placed that it will
just enter the star gear. The position of the disk c^ that
carries the pin may be changed in relation to the index gear b
by means of the slot Cs, so that the time that the pin enters
the star gear may be altered.
12. Timing tlie Nippers. — In order to time the nip-
pers, set the index gear at 9 and loosen the nipper cam,
which is bolted to a sleeve on the cam-shaft. This sleeve
carries a disk that has a slot similar to c^, Fig. 7, and the
cam is fastened to the sleeve by means of a bolt passing
through the cam and entering the slot, thus allowing the
§23
COMBERS
19
cam to be moved on the sleeve. This cam should be fixed
on the sleeve in such a position that it will cause the screws ?\,
Fig. 3, just to leave the stands when the index gear is at 9.
By placing a slip of paper between the screw zVand the stand
and pulling on it lightly, at the same time turning the
driving shaft of the machine, the time when the paper is
released will denote the time when the screws Za are leaving
the stands.
If it is not possible to have the screws z, leave the stands
when the index gear is at 9, because of the relative positions
Fig. 7
of the cylinder shaft and the cam-shaft, the gear on the
cam-shaft may again be moved out of gear and the cam-
shaft turned until the nipper cam is in the desired position,
when the gear may again be meshed with the index gear.
In order to avoid the liability of having to move the cam-
shaft when timing the nippers, the gears on the cam-shaft
and cylinder shaft may be meshed when the index gear is
at 17 and the bowl on the nipper cam is in the position it
should be when the rods g, Fig. 5, are set. The relative
20 COMBERS §23
positions of the cylinder shaft and cam-shaft will then be
such that the motions received from the cam-shaft may be
adjusted by slightly altering the positions of the cams on
their respective sleeves, which are keyed to the cam-shaft.
The nipper knife should leave the cushion plate at
about 42; this can also be set by placing paper in the nippers
and noting when it is gripped as the driving shaft of the
machine is turned. If, after having set the cam so that the
screws z'a. Fig. 3, leave the stand at 9, the knife does not
leave the cushion plate at exactly the proper time, a further
adjustment of the nippers may be made by means of the
screws ^6, g^-, Fig. 5.
The lever g^ gives motion to the nipper shaft g^ through
the casting^, by means of the screws ^s, ^s. If, therefore,
the nipper cam is not placed in position for the screws z'a.
Fig. 3, to leave the stands when the index gear is at 9, the
screws on the casting g^ may be adjusted, changing the rela-
tive positions of the nipper shaft g^ and the cam. These
adjustments may be made until the relative position of the
nippers with the cam-bowl in the cam-course is correct when
the cam-bowl is at any point in the course.
13. Placing the Detaching Roll and Top Roll in
Position for Detaching. — The lifter cam/,. Fig. 8, which
controls the leather detaching roll q, next requires adjusting.
This cam is mounted and fastened in the same manner as
the nipper cam and should be placed in position so that the
leather detaching roll will come in contact with the fluted
segment when the index gear is at 6f. This may be tested
by placing strips of paper on the fluted segment and observ-
ing when they are held between the segment and the roll.
14. Distance of Blocks From Bearings of Detach-
ing Roll When Bearing on Segment. — The two last set-
tings mentioned in the list of settings may now be made.
The lifter cam should be in such a position that, when the
roll touches the segment, the blocks 4, Fig. 8, will not be in
their lowest positions, but will continue to move down as
the cam revolves. When the blocks L are in their lowest
23
COMBERS
21
positions, there should be a space between them and the brass
bushings of the leather detaching roll equal to a No. 23
comber gauge. The blocks may be adjusted by the screws
/«, Fig. 8, so that the distance between them and the brass
bushings may be regulated when the cam has lowered the
Fig. 8
blocks as far as possible. When this setting has been made
as described, it is certain that the detaching roll is properly
in contact with the fluted segment.
15. Setting the Top Roll From Leather Detaching
Roll. — When the detaching roll is properly in contact with
22 COMBERS §23
the fluted segment, the top roll should be set from the
detaching roll with a No. 21 comber gauge. This is accom-
pHshed by loosening the setscrews that hold the supports
for the bearings of the roll to the shaft /,.
16. Removal of Detaching Roll From Detaching
Position. — The lifter cam should now be in position so
that, in addition to causing the detaching roll to come in
contact with the segment at 6f and moving the blocks the
required distance from the bushings, it will also remove the
detaching roll from the segment at Oi. This can also be
tested by paper placed between the segment and the roll,
which should release the paper at 9h If the cam is in its
proper position when the detaching roll touches the segment,
but is not in a position to remove the detaching roll at the
proper time, it can be remedied by an adjustment provided
on the lever k^, Fig. 8, similar to the one described in con-
nection with the lever ^3, Fig. 5. This adjustment is for the
purpose of regulating the position of the lifter shaft k in
relation to the cam, so that the latter may be in a position
to place the roll in the correct positions at the given times.
Any adjustment made by the screws k, will change the dis-
tance between the blocks /^ and the brass bushings on the
leather detaching roll.
17. Timing the Motions of the Delivery Roll. — The
cam that gives to the delivery roll the rotary motion, which
is transmitted to the detaching roll and the top roll, should
be set so that when the index finger is at about I2, the
cotton will be started back to be pieced up and, when the
index is at about 6, this motion should be reversed and
the cotton delivered. The cam that places the pawl of this
motion in and out of contact with the gear 2%, Fig. 9, is
joined to the cam that imparts the rocking motion to the
pawl and, when the latter cam is set, the former is usually
very near its correct position. It is capable of being
adjusted independently, however, so that it will correctly
govern the time that the pawl is placed in, and taken out of,
contact with the gear v^. The pawl is allowed to come in
23
COMBERS
23
contact with the gear when the index gear is at about li, the
time that this pawl is placed in contact with the gear and
taken out of contact governing the amount of overlap in the
piecing. The usual amount of overlap is about f inch, or
practically halt the length of the fibers.
18. Tlie Toi^ Comb. — The time when the top comb
should first be do\\-n varies from 5 to 6. The top comb
should always be down when the detaching commences.
The timing of the comb may be regulated by moving the
'^^-''.
Fig. 9
cam Hi, Fig. 4. which is on the cylinder shaft and imparts
motion to the top-comb shaft «,.
19. In regard to settings and timings it may be stated
that more waste may be removed by feeding at a late period,
by nipping later, by closer settings of the nippers and top
combs to the cylinders, and by increasing the angle of the
top comb. The following are good settings and timings
for a comber running a lap of 260 grains of Egyptian cot-
ton with a staple of 1| inches and removing about 16 per
cent, waste:
24 COMBERS §23
Feed-roll from delivery roll . . iH-inch finger gauge
Cushion plate from delivery roll Ins-inch finger gauge
Distance of screws /a from stands i-inch step gauge
Distance of nipper from half lap No. 20 comber gauge
Angle of top comb 28°
Top comb from fluted segment . No. 20 comber gauge
Distance of blocks h from bear-
ings of detaching rolls .... No. 23 comber gauge
Top roll from leather detaching
roll No. 21 comber gauge
Feeds at 5, index gear
Nipper knife leaves cushion plate
at 42, index gear
Nipper knife touches cushion
plate at 8f , index gear
Leather detaching roll touches
segment at 61, index gear
Leather detaching roll leaves
segment at 91, index gear
Delivery roll reverses at .... 2, index gear
Delivery roll delivers at ... . 62, index gear
Top comb down at 6, . index gear
20. Because of the difference in construction between
double- and single-nip combers, there is a slight difference in
timing. This is shown by the following comparison of these
types when equipped with the quadrant motion. This timing
is for sea-island cotton. Single-Nip Double-Nip
Feeds at 5 4i and 14i
Nippers close 91 91 and 194"
Leather detaching roll touches
segment 6f 6f and 16f
Delivery roll reverses .... 20f 20f and 10|
Delivery roll delivers 6 61 and I64
Top comb down Si 42 and 142
Clutch thrown in 20i 20i and lOi
21. In some cases where especially fine yarns are to be
produced, the percentage of waste taken out by the combing
§23 COMBERS 25
is not considered sufficient and double combinff is per-
formed. Where this process is used, the cans of sliver
delivered from the combers may be placed at the back of the
sliver-lap machine and the entire process repeated, or as is
more often done, the cans may be placed at the back of a
ribbon-lap machine that, instead of having lap rolls, has
a back similar in construction to that of the sliver lap, each
delivery, however, being fed only 8 or 10 ends. The laps
from this machine are then placed on the lap rolls of the
comber. After the combing operation the cotton is sub-
jected to the drawing processes, whether it has been combed
once or twice.
MANAGEMENT OF THE COMBER ROOM
22. Important Points. — As the comber room uses
only the best cotton, from which the finest and the special
grades of yarn are produced, there are a great many important
points to be looked after, especially those in relation to
economy.
1. The needles on the half lap should receive careful atten-
tion and any that are bent or crooked should be straightened
by a pair of special pliers provided for this purpose. If
there are too many bent or broken needles, the half lap should
be taken out and new needles put in. Extra half laps are
usually provided so that the machine will not have to remain
idle during the time that a half lap is being repaired.
If the several matrices to which the needles are attached
are not carefully joined to each other, there will be a large
accumulation of waste, which will become so strongly fast-
ened that the brush will not be able to remove it. These
collections of cotton should be removed by hand at the back
of the comber.
2. The brushes that clean the half laps should have the
waste removed from their bristles about once a month.
When performing this operation, a rake, shown in Fig. 10,
is used. When cleaning the brushes, the feed-roll should be
thrown out of gear and the ends allowed to run through so
26
COMBERS
23
that the dust will not get into the good cotton. The laps
should also be protected by a cloth.
As the bristles on these brushes wear down, they should
be readjusted so as to be kept in contact with and clean the
cylinder needles. As the brushes become smaller by the
bristles being worn down, it is sometimes found necessary
to change the speed of the brush shaft. Through continued
wear and readjustment the bristles become short and soft
and the old brushes should then be replaced by new ones.
When replacing the old brushes with new ones, a complete
new set should be used and care should be taken that they
are all of equal diameters, as all the brushes for the heads of
a comber are mounted on one shaft.
3. The condition of the leather detaching roll has much to
do with the quality of the work. This roll should be per-
fectly true and should be varnished about once a week.
Fig. 10
Care should also be taken in oiling this roll to see that suffi-
cient oil is put on its bearings to give them proper lubrication,
and at the same time that the amount is not so large that
the oil will run out on the web and cause bad work. Thick
and thin places in the web are sometimes an indication that
the detaching roll is in poor condition, that is, improperly
covered or varnished, or that the bearings of the roll are not
properly lubricated. This defect may also be caused by the
detaching roll not touching the segment at the proper time.
4. Top combs should be looked after very carefully, since
if the needles are bent, hooked, or broken out, the web of
cotton will be stringy when it enters the pan, due to the fact
that the cotton passing through is not properly combed by the
top comb. These should be brushed out twice a day with a
§23 COMBERS 27
stiff brush furnished for this purpose. They should also
be looked over once a week, when the needles should be
straightened and smoothed or, if in the opinion of the one
looking them over, their condition is not good enough, the
top comb should be taken out and reneedled. If the points
of the needles are only slightly damaged, they may be
remedied by being rubbed with a piece of fine emery cloth
fixed to a board.
5. The table, table calender rolls, and top of the coiler should
be cleaned and polished with whiting twice a week and all
dirt kept from these parts of the machine.
6. The payis should be wiped out with whiting at least
once a week and should always present a bright appearance;
all dirt should be kept out of the flutes of the feed-rolls,
delivery rolls, and top rolls.
7. While cleaning the front of a comber the machine
should be stopped, because all loose fly, dirt, and dust that
have been taken out of the cotton and have accumulated on
the parts to be brushed are liable to return to the combed
cotton. When starting the comber, the end should be
broken at the coiler and allowed to run about half a minute
before it is pieced up, to insure that no dirty cotton passes
through with the good cotton into the can.
The ceiling should be brushed and hangers and pulleys
cleaned at a time when the combers are not running. When
the combers are started again after the ceiling has been
cleaned, the ends should be broken at the coiler and all dirt
brushed from the front of the comber before the end is
pieced up.
8. In the comber, single and double should be looked out
for. If an end breaks on the table or in one of the pans and
the other five ends continue to run through the draw-box, it
makes the resulting sliver too light. Whenever an end is
seen to be broken, it should be pieced up and the sliver that
has been delivered into the can for the period that the end
has been broken should be removed. In the case of double
— that is, where one end has broken on the table and after
a time has doubled on itsslf and been drawn along by the
28 COMBERS §23
friction of the other slivers — the amount of sliver delivered
into the can during that period should also be removed.
23. Oiling and Cleaning. — In the comber, as in every
other machine in a mill, certain parts must be oiled; this
should be periodically attended to. All the more important
parts ought to be, and generally are, oiled by one whose
special duty it is to attend to this. These parts consist of all
the gearing and motions that need oiling in the headstock of
the comber, all the cam-courses and cam-bowls and the loose
pulleys. If the cam-courses and cam-bowls are allowed to
become dry, the bowls will wear away very quickly and
become too small for the course, thus causing bad work.
About once or twice a year all the working parts of the
comber should be taken down, thoroughly cleaned, and any
parts needing repairs should be attended to, such as cushion
plates recovered, needles repaired, new brushes put in, or
the fillet on doffers replaced. When this has been attended
to, the parts should be put together and set as previously
described.
24. Waste. — The amount of waste being removed by
the various machines combing different kinds of cotton should
be ascertained often enough to insure that the proper percent-
age of waste is being taken out. This is done as follows:
After making certain that the laps are all right and that the
comber is working properly, the waste cans at the back are
removed and boards placed on supports in such positions that
the waste will be delivered from the doffers on the boards.
The boards generally used for this purpose are about I inch
thick and have their tops varnished in order to obtain a
smooth surface. The comber is then operated until the
doffer comb is at the lowest part of its swing, after which the
waste at the back is all removed and the sliver broken at the
point where it is leaving the front calender rolls. The com-
ber is next started and allowed to run untiK it has made
about 40 nips. The cotton delivered by the front calender
rolls is then kept as one portion, while the waste delivered on
the boards is taken as another portion. These two portions
§23
COMBERS
29
of cotton are placed on a pair of scales, Fig. 11, which, instead
of denoting weight, denotes the percentage of waste.
Another method for finding the percentage of waste is
to weigh each portion and add the weight of waste to the
weight of combed cotton and divide this result into the
weight of the waste. If the comber is taking out too much
or too little waste, any of the settings and timings that have
been described as regulating the amount of waste may be
changed. The amount of waste will vary under the very
best circumstances from 1 to 3 per cent., and due allowance
should be made for this.
Example. — If 60 grains of sliver is delivered from a certain comber
in a given number of nips and the waste amounts to 15 grains, what
percentage of waste is being removed?
Solution. — 60 gr. weight of sliver
15 gr. weight of waste
75 gr. total weight
15 -f- 75 = .20, or 20 per cent. Ans.
25. Speed of Combei'. — In speaking of the speed of a
comber it is said to make so many nips per minute and not
revolutions per minute, as in the case of the other machines
that have been described. By this is meant that every time
30 COMBERS §23
the nipper jaws close a nip is made, which in the case of a
single-nip comber is one for each complete revolution of the
cylinder shaft. In the double-nip machine the comber makes
two nips to every complete revolution of the cylinder shaft.
A good working speed for a single-nip comber is about
85 nips per minute, while a double-nip comber produces
good work when running 120 nips per minute.
26. The weight of a comber with six heads is about
3,500 pounds, and with eight heads 4,500 pounds. A single-
nip comber with six heads requires f horsepower and with
eight heads I horsepower, while a double-nip comber of
six heads requires I horsepower and with eight heads
8^ horsepower. The floor space occupied by a single nip
6-head machine for Sf-inch laps, and also for an 8-head
machine of the same type is about 13 feet by 3 feet 5 inches
and 16 feet by 3 feet 5 inches, respectively.
The production of a single-nip comber varies from
225 pounds to 450 pounds per week of 60 hours, while the
production of a double-nip varies from 300 pounds to
550 pounds per week of 60 hours.
FLY FRAMES
(PART 1)
GENERAL CONSTRUCTION OF FLY
FRAMES
INTRODUCTION
1. After the sliver has been formed at the card and its
structure improved at the drawing frames or perfected by the
use of combing machinery, much foreign matter and impuri-
ties have been removed from the raw stock, the fibers have
been carded, straightened, and laid parallel to one another,
and the sliver has been evened throughout its whole length,
but it is still in too bulky a form and must be further
attenuated before it is sufficiently fine to be run through the
machine that completes the operation of making it into yarn.
In addition to attenuating the sliver until the required
weight per yard is obtained, the opportunity is also taken, in
several machines, to multiply the number of doublings, which
not only tends to retain the evenness of the sliver produced
at the drawing frames, but also to improve on it. The sliver,
as it is attenuated by the processes that follow the drawing
frames, is known as roving; an idea of the extent to which this
roving is drawn out before it is considered suitable to be spun
into yarn by the mule or spinning frame may be gained by
considering that a common weight for sliver at the drawing
frame is 60 grains to the yard, from which roving weighing
1.19 grains to the yard is commonly made before being spun
into yarn, the sliver thus having been reduced in weight in
about the proportion of 50 to 1. For finer work a sliver of
For notice of copyright, see page immediately following the title page
g24
2 FLY FRAMES §24
45 grains to the yard might be made into a roving of .3 grain
to the yard or an attenuation in the proportion of 150 to 1.
It would be impossible to properly perform this attenuation
by one process, and consequently the cotton must pass
through three or four machines before going to the mule or
spinning frame.
The machines used in modern mills to effect this attenua-
tion are known collectively as fly frames, although some-
times called speeders. The expression fly frames should
be applied generally to all these frames as at present con-
structed, since the term speeder really refers to a machine
that is not now made and is only in use to a very small
extent. It is probable, however, that the term has obtained
such a hold in some manufacturing districts that it will never
pass into disuse. Fly frames are divided into slubbers, hiter-
mediates, and roving frames where three frames are used
between the drawing and spinning frames. Where four
frames are used they are generally known as the slubber,
intermediate, roviyig frame, and jack frame; in this case the
word jack is used to indicate a fine roving frame, sometimes
called a jack roving frame. The frame following the inter-
mediates is sometimes called a fine frame. A much better
method of naming the machines, which is used in some parts
of the United States and should be uniformly adopted, is to
speak of the first machine after the drawing as the slubber;
the last machine before the spinning as the roving frame;
while the intermediates, if more than one in number, are
spoken of as the first and second intermediates, respectively.
All the machines classed under the head of fly frames are
practically of the same type of construction, the only differ-
ences being in the details. One point to be noted, however,
is that since the roving is gradually drawn finer at each
succeeding process, it is necessary that certain parts of
the intermediate frame should be smaller than the same
parts of the slubber, in order to accommodate themselves
to the decreasing size of the roving; the same is also
true in regard to the roving frame as compared with the
intermediate.
J 24
§24 FLY FRAMES 3
2. Fly frames have as their objects: (a) the reduction of
the thickness of the sliver, (d) the evening of the product,
{c) the twisting of the roving, (d) the winding of the roving
on a bobbin. The attenuation of the sliver renders the third
object necessary, since, as the sliver is reduced in size, it
naturally becomes weaker and must be twisted in order to
enable it to hold together in passing to the next process.
Twisting the sliver is followed by winding it on a bobbin,
since the reduced sliver must be laid in such form as will
allow it to be rapidly revolved around a spindle. The
last two objects will be found to be far more difficult of
attainment than the first.
The principles adopted to obtain the objects mentioned
are: (a) roll drafting; (d) doubling; (c) securely holding
the roving at two points, viz., the bite of the delivery rolls
and the bobbin on which the roving is wound, and also
passing it through what is known as a f/yer, which revolv-
ing rapidly inserts the necessary twist; {d) having either
the surface speed of the bobbin exceed the speed of the
flyer or the speed of the flyer exceed the surface speed of
the bobbin, the excess speed of one part over the other in
either case being sufficient to take up the roving delivered
by the delivery rolls. Although these are the four main
principles, several minor mechanical problems present them-
selves in the construction and operation of fly frames and
are solved by the adoption of other mechanical principles,
as will be observed later.
As previously mentioned, slubbers, first and second inter-
mediates, and roving frames differ very slightly in construc-
tion, the principal point that would be noticed by a person
looking at the different machines being in the manner of
feeding. With the slubber, the cans from the drawing
frames are placed directly behind the machine and the sliver
fed from the cans, while with the fly frames that follow the
slubber, creels are provided in which to set the bobbins of
roving, which is the form in which the cotton is delivered
by all of these machines.
FLY FRAMES §24
THE SLUBBER
PASSAGE OF THE STOCK
3. As the slubbei* may be considered the simplest form
of fly frame, and as it is the first machine in the series, it
will be referred to in giving a general description of the con-
struction of these machines. Fig. 1 shows a front view of a
portion of a slubber, while Fig. 2 gives a view of the back
of the same machine; Fig. 3 is a cross-section through the
essential parts of the machine. Referring to Fig. 3, the
cans a that come from the finisher drawing frame are placed
behind the slubber and the sliver b passed to the guide
board c. In the slubber, which in this respect is unlike any
of the other fly frames, no doubling takes place, each end
of sliver being treated individually. From the guide board c,
the sliver passes over the lifter roll d, through the traverse
guide e, and then through three sets of rolls /a, /,,/,, which
insert the necessary draft. From the drawing rolls, the
sliver passes through the upper part of the flyer g- and then
out at its lower part, where it is wound around an arm sup-
ported by the flyer. From this arm, the cotton, which having
been reduced in size by the drawing rolls of the slubber is
now known as roving, passes to the bobbin //, on which it is
compactly wound. The flyer g is supported, by the spindle /,
while the bobbin h rests on a flange that forms the upper
part of the gear //,. The gear //, is known as the bobbin
gear and revolves loosely on the bolster k, Fig. 9. In Fig. 3,
two ends are shown at the front, although for convenience
only one sliver is shown at the back. Each end shown at the
front is produced from a separate sliver fed behind the frame.
PRINCIPAI^ PARTS
4. The guide board c through which the sliver passes as it
comes from the can is simply a long board with guide holes
cut in it at suitable intervals, to prevent one sliver from
coming in contact with another. The lifter roll d extends
224
' o o o o o
o o
i
§24 FLY FRAMES 5
the entire length of the frame. At one end it carries a
sprocket gear driven by a chain that derives its motion from
a sprocket gear on the bottom back drawing roll. The lifter
roll revolving in the direction in which the sliver is moving
serves to reduce the strain that would be brought on it should
it be drawn up by the action of the drawing rolls alone.
The traverse guide e, by guiding the sliver first to one
part of the drawing rolls and then to another, prevents con-
tinual wear on any one part of the rolls. As the objects of
traverse motions as well as their different constructions
have been dealt with, no further mention of them need be
made here.
The drawing rolls of a slubber may be either of the metallic
or of the common type, although when running very fine
work the common rolls are almost universally used. In the
fly frames that follow the slubber, which deal with the stock
after it has been attenuated considerably, common rolls are
almost wholly adopted. There are usually three sets of
drawing rolls in fly frames, and whether metallic or com-
mon, they are similar in construction to those in a drawing
frame. Clearers are also provided for both top and bottom
rolls, although it is frequently the custom to run intermediate
and roving frames without bottom clearers.
5. The Flyer. — A view of the flyer, to which the cotton
passes from the front drawing rolls, is shown in Fig. 4. It
consists of a boss g^ that contains a hollow portion g^ into
which the spindle projects, two downward projecting arms, or
legs,g3,g^, and a presser g^. The upper portion of the boss of
the flyer is carefully rounded and smoothed and at its top con-
tains a hole that extends downwards and has an opening g^
on each side. The projecting leg g^ is solid and serves
simply as a balance for the other leg ^4. The leg g^ is
hollow and carries two lugs, or projections, ^7, .^r that act as
bearings for the presser. The presser, or as it is sometimes
called, the presser {inger, is, as shown in the figure, a round
rod hooked at its upper end and bent to a right angle at its
lower end. The hollow leg g^ is slightly tapered at its
FLY FRAMES
§24
lower end, and the presser is so shaped at this point that it
forms a circular clamp through which the lower end of the
leg g* is passed. The inner part of the presser is flattened
out into a palm, or paddle, g^ and is formed with a guide eye.
The horizontal part of the presser is of such a length that the
guide eye in the palm always comes about opposite the cen-
ter of the bobbin when the bobbin is empty. The roving in
Fig. 4
coming from the delivery rolls passes into the hole at the
top of the boss of the flyer and out through the opening at the
point ge, as shown in Fig. 4. It is then wound partly around
the boss, passes down the hollow leg g^, and is wrapped
around the horizontal part of the presser once or twice.
It then passes through the guide eye in the palm to the
bobbin, on which it is wound. Wrapping the roving twice
§24 FLY FRAMES 7
around the horizontal arm of the presser is the more com-
mon practice, although when flyers are new and compara-
tively rough once around will be found to be sufficient. If
the leg gt of the flyer were made perfectly tubular, it would
be difficult to thread the roving through it in case of break-
age. Therefore, the hollow leg is not completely closed, but
an opening remains from top to bottom, shown slightly
curved in Fig. 4, through which the end of roving may be
passed. As this slot is curved it prevents the roving flying
out when the flyer is revolving at a high speed. Sometimes,
especially for coarse work or machines that are not intended
to run at a high speed, the slot is straight.
The flyers are carefully constructed of such a quality of
material as will take and maintain a high polish, as it is
necessary that all the parts of the flyer with which the cotton
comes in contact shall be perfectly smooth. Otherwise,
there is a tendency to develop undesirable friction as the
roving passes through the eye and down the leg of the flyer,
and in some cases small lumps of cotton are thus formed,
which pass forwards at intervals, deteriorating the quality of
the yarn.
Certain parts of the flyer have an important bearing on the
hardness or softness of the bobbin that is made. By this is
not meant the hardness or softness of the roving itself,
which is determined by the amount of twist inserted, but the
feel of the completed bobbin. If the roving were wound on
the bobbin without the application of any pressure, the result
would be a soft, loosely wound mass of material. To pre-
vent this the flyer is so constructed that the palm g^ exerts a
slight continuous pressure on the bobbin as the roving is
being wound thereon. This is done by making the vertical
rod of the presser sufficiently heavy to tend to fly outwards
as the flyer revolves, which it does at a high speed. The
result of this is to throw the palm g^ inwards, since tlie
vertical rod is capable of swinging partially around the
leg g*. There is some tendency also for the palm itself to
fly outwards due to centrifugal force, but the excess weight
of the vertical rod and its greater distance from the spindle
8 FLY FRAMES §24
I are sufficient to overcome the centrifugal force of the
palm g^ and bring a slight pressure constantly to bear
on the bobbin.
By altering the relative weights of the vertical rod
and the palm, almost any degree of firmness of the
full bobbin can be obtained, but this is a point for the
machine builder to experiment with and decide on before
building the frame, and should not be changed after the
machines are installed in the mill unless so advised by
the builders.
Bobbins can be made harder by inserting more twist
in the roving, as well as by increasing the pressure of
the palm on the bobbin.
6. Tlie Spindle. — The spindle, as shown in Figs. 3
and 5, is a long steel rod. Its upper end, which is
tapered, extends into the hollow part g^, Fig. 4, of the
3 flyer, where it comes in contact with a wire pin that is
fitted into holes bored in the sides of the flyer. This
pin fits into the slot in the upper end of the spindle and
in this way the two parts are made to act as one. At
its lower end the spindle is slightly reduced in diameter,
and at its extreme end tapers to a point. This end of
the spindle rests in a footstep, which is generally a
recess in a bracket, except on English types of frames,
where it is a removable piece of metal.
Spindles are made of hardened steel and ground to
exact dimensions. They vary from f inch to \ inch in
diameter according to the frames for which they are
intended, being of smaller diameter and shorter on
roving frames and of greater diameter and longer on
slubbers. The spindles in all fly frames are arranged
in two rows, one behind the other. The spindles in
the back row do not come directly behind those in the
front row, but are generally set in such a manner that a
spindle in the back row will come half way between two
tof the spindles in the front row, as shown in Fig. 6; this
figure gives a view of five spindles, flyers, and bobbins
Fig. 5
24
FLY FRAMES
9
as they would appear when looked at from above. It is
customary to describe the gauge of the spindles, that is, the
distance from the center of one spindle to the center of
the next spindle in the same row, as so many inches; for
instance, 6 inches, etc. Another method is to state the
number of spindles in a certain number of inches; for
instance, if the distance from the center of one spindle to
the center of the next spindle in the same row is 6 inches,
then the frame is spoken of as having 6 spindles in 18 inches,
there being two rows of spindles and the spindles in each
Fig. 6
row being spaced alike. The total number of spindles in a
frame varies and is dependent on the gauge of the spindles
and the length of the frame. Fly frames as a rule do not
often exceed 36 feet in length, and are seldom built less than
20 feet in length.
7. The Footstep. — The footstep bearing, or foot-
step, y» in which the base of the spindle rests is shown in
Figs. 3 and 7. These steps are bolted to the step rail /,
that extends the entire length of the frame, very near the
floor; a cross-section of the step rail is shown in Fig. 8. It
10
FLY FRAMES
§24
will be noticed that both sides of the rail are made alike
and will thus allow the footsteps to be placed on each side;
the two rows of spindles necessitate this arrangement. At
frequent intervals along the step rail are set footsteps that
carry a bearing for the spindle shafts p. The two spindle
shafts, one for each row of spindles, carry gears p^ that
drive gears y, setscrewed to the spindles, and thus give
the spindles their motion. The spindle shafts, spindle
steps, step rails, and the gears both on the spindles and
Fig."?
Fig. 8
on the spindle shafts are completely enclosed in order to
prevent any dirt or loose cotton from collecting on the
various parts.
8. Tlie Bolster. — As the spindles are of considerable
length, it is absolutely necessary that some bearing be pro-
vided for them in addition to the support formed by the step,
in order to support them in a vertical position, and so that
they may run true. This is accomplished by having a
bolster, shown in Fig. 9, through which the upper part of
the spindle projects. The bolster consists of a collar k,
through which the spindle passes, the upper part being bored
to such a diameter as will just fit the outside diameter of the
spindle. At the lower part of the bolster is a shoulder k^,
that fits a recess in the bolster rail, to which it is firmly
bolted. The bolster rail, a cross-section of which is shown
in Fig. 10, is made alike on both sides, in order to provide
for bolsters for each row of spindles.
§24
FLY FRAMES
11
At one time, the collars used to support the spindles verti-
cally were rather short, not projecting much above the bolster
rail, but it is now the universal custom to use long collars,
such as that shown in Fig. 9. The advantage of the short
collar was in being able to use a
bobbin of less outside diameter and
thus have more stock wound on it, as
the shortness and small diameter of the
collar did not require as great an open-
ing, or hole, in the bobbin; consequently,
allowing the outside diameter of the
bobbin to be less in proportion. The
disadvantage of the use of the short
collar was due to the fact of its support-
ing the spindle at a point a consider-
able distance from its upper end, even
when the bobbin rail was at its highest
position. As the bobbin rail moved
downwards this defect was accentuated,
Fig. 9
Fig. 10
and since the spindle and flyer ran at high speed and had no
support at any point in the upper half of the length of the
spindle, this tended to develop vibration and wear. In using
such a collar as is shown in Fig. 9, the bearing part that sup-
ports the spindles is placed a considerable distance above
12
FLY FRAMES
24
the bolster rail and several inches nearer the top of the
spindle, which is conducive to steady running of the spindles.
The spindle has a bearing only in the upper part of the
collar, for about 2 inches, the lower part being bored out to
a larger diameter than that of the spindle. This
method of construction reduces the amount of
friction that would take place should the spindle
bear against the entire length of the collar.
9. The Bobbin. — Fig. 11 shows a cross-
section of a long-collar bobbin used on fly
frames. Such bobbins are usually constructed
of wood, although sometimes made of paper or
corrugated metal. The cheapest bobbins are
those made of plain wood without any protec-
tion whatever, but it has been found an advan-
tage to have the lower end of the bobbins
protected by a wire placed in a groove, or even
by a metal shield surrounding the base of the
bobbin and partially embedded in it. The
cost of a bobbin constructed in this manner
(TTll
, (
^K
\
i h,
^^
mi
). !,
f
Fig. 11
Fig. l:^
is higher, but breakage and wear and tear of the bobbin
are very much less.
When the bobbin is in position on the frame, the smaller
hole at the top of the bobbin receives the spindle and the
larger opening encloses the collar, which is thus entirely
covered by the bobbin.
14
FLY FRAMES
24
The bobbin gear, shown in Fig. 12, rests on a projection X-,,
Figs. 3 and 9, carried by the bolster. It is not fastened in
any manner to the bolster and is thus free to revolve loosely
around the long collar that furnishes a bearing for the
spindle. Motion is imparted to the bobbin gear Zfi by means
of a gear h^ setscrewed to the bobbin shaft /;., which is
supported by bearings fastened to certain of the bolsters.
As shown in Fig. 12, the bobbin gear carries a flange / on
which the bobbin rests. A projection l^ on this flange
extends into one of several slots in the base of the bobbin,
and thus drives the bobbin. In case
long collars are used on bolsters, the
collar extends for some distance into
the bobbin, and it is very essential that
the bobbins on any fly frame should be
well constructed to exact dimensions, so
as to grip the bobbin gear well and fit
the spindle and collar as closely as pos-
sible without binding. Bobbin gauges
are now made by several manufacturers
of fly frames to test accurately the
inside and outside diameters of a bob-
bin, and it is advisable to have a set of
these gauges with which to test new
bobbins before they are run.
The bobbin gears, the gears on the
bobbin shafts, the bobbin shafts, the bob-
bin rail, and the lower ends of the bol-
sters are completely enclosed, in order to prevent as far
as possible any fly or dirt from collecting on the various
parts. Fig. 13 shows the connection between those parts of
a fly frame that have been described, such as the footstep,
spindle, bolster, bobbin rail, step rail, flyer, etc. It will be
noticed that two rows of spindles are shown, many of the
parts in one row being shown in section, while the parts in
the other row are shown in full. By comparing this figure
with those that show the different parts separate, a good
idea will be obtained of the relative position of each part.
/ l\
N %
LZJiZ]
Fig. 14
§24
FLY FRAMES
15
The manner in which the roving is built up on the bobbin
is shown in Fig. 14. It is wound in close spirals around the
empty bobbin until the entire length of the bobbin, with
the exception of about i inch at the top and 1 inch at the
bottom, is covered; the complete length of roving that
extends from the bottom to the top of the bobbin is known
as a layer. It is the object to build up the bobbin with
cone-shaped ends, as shown in Fig. 14; consequently, each
succeeding layer on the bobbin must be a little shorter than
the preceding one, this being continued until the distance a b,
Fig. 14, is reduced to the distance c d.
Fig. 15
10. Hank Clocks. — Fig. 15 shows an instrument known
as a hank clock, which is attached to all fly frames. The
object of the clock is to register the number of hanks of
roving that pass the delivery rolls. This clock is usually
situated at the foot end of the frame and has attached to it a
worm-gear that is driven by a worm situated on the end of
the front roll. By considering the diameter of the front roll
and by having a suitable number of teeth in the worm-gear
and the gears forming the clock, the exact length that passes
the delivery rolls will be indicated on the hank clock, the
16 FLY FRAMES §24
length, however, being expressed in hanks. This clock is
read on the same principle as most clocks or indicators.
The short hand indicates the number of hanks, while the long
one indicates the fractions of a hank in one-hundredth parts.
METHOD OF INSERTING TWIST
11. It is necessary to insert a small number of turns
per inch in the roving after it leaves the front drawing rolls,
in order to enable the fibers to hold together and withstand
the strain of being wound on the bobbin and unwound at the
next process. In common with all cotton-yarn-preparation
machines where twist is inserted in a strand of material, the
strand is held at one point while it is revolved at another.
Strictly speaking, the strand is also held at this point, but
by a revolving mechanism. In fly frames, the roving is
gripped between the bottom and top front rolls as it is being
delivered, and is also held by the bobbin on which it is
being wound, although as the roving passes through the
hole in the boss of the flyer and down the hollow leg, the top
of the boss of the flyer practically forms the termination of
the grip of the roving at this point. Consequently, the
roving may be considered as being firmly held here, and
since the spindle and flyer are making from 600 to 1,400
revolutions per minute, the roving is being twisted all
the time.
The rolls of course are constantly delivering roving and
the bobbins taking it up as fast as it is delivered, so that
while the roving that is being twisted at any one time is
in a suitable position to receive the twist, a new supply
is constantly being brought under the twisting operation, at
a regular and uniform rate of speed, and that portion
already twisted is passing from the influence of the twisting
mechanism and on to the bobbin. In ascertaining the
amount of twist per inch inserted in the roving, it is there-
fore necessary to obtain data as to the number of inches of
roving delivered by the rolls during a certain period, and the
number of turns made by the spindle during the same period.
§24 FLY FRAMES 17
If, for example, the flyer makes 25 revolutions while the rolls
deliver 12^- inches of roving, then there will be 25 -^ 122 = 2
complete turns put into an inch of the roving delivered.
WINDING THE ROVING ON THE BOBBIN
12. The front rolls of a fly frame rotate at a constant
rate of speed while the machine is in motion; hence, a
uniform length of roving is being constantly delivered.
Suitable means must be provided for winding this roving on
to the bobbin as fast as it is delivered, but at the same time
the mechanism for winding must be such that the roving
will not be broken or strained. As shown in Fig. 13, the
flyer is supported by the spindle, which also imparts a rotary
motion to it, while the bobbin, although placed on the
spindle and rotating on the same center as the flyer, is
driven by an entirely separate mechanism. The roving is
wrapped around the bobbin because of the difference in
the velocity of the bobbin and the flyer eye, since if both
revolved in the same direction and at the same speed the
roving could not be drawn through the eye of the flyer and
wound around the bobbin. In considering the action of the
flyer and bobbin in winding the roving about the latter, it
will be found that there are several possible methods by
which this may be accomplished.
1. A uniform rotary motion may be imparted to the flyer
alone, the bobbin remaining stationary. This method, how-
ever, is not practicable, because as the roving is wound
around the bobbin the diameter of the latter increases, and
therefore a greater length of roving will be required for
each successive revolution of the flyer; hence, if a uniform
amount of roving is delivered by the drawing rolls the
strain on it will quickly increase until sufficient to cause it to
break. This difficulty might be remedied by uniformly
decreasing the speed of the flyer as the diameter of the
bobbin increases, but as the speed of the flyer governs
the amount of twist in the roving, a variation in the turns
per inch would ensue in this case.
18
FLY FRAMES
§24
2. A rotary motion may be given to both the flyer and
the bobbin, the speed of the flyer being just sufficiently in
excess of that of the bobbin to wind the roving on to the
latter as fast as it is deHvered by the drawing rolls of the
frame. Since in this case the flyer is moving faster than
DO"
Fig. 16
TO
Fig. 17
the bobbin, or leading it, the arrangement is known as a
flyer lead, and a frame thus equipped is called a flyer-lead
frame. Fig. 16 illustrates the relative positions of the flyer,
bobbin, and roving in a flyer-lead frame. In considering the
§24 , FLY FRAMES 19
operation of this arrangement it will be remembered that in
a given length of time the front drawing rolls of the frame
deliver a definite length of roving. Assume, for the purpose
of illustration, that this definite length is 6 inches. Then, in
order to wind this length of roving on to the bobbin in a
flyer-lead frame, the eye of the presser on the flyer must
move just 6 inches farther than a point on the surface of the
bobbin during the length of time that it takes for the draw-
ing rolls to deliver 6 inches of roving. This gain, or lead,
of the flyer over the bobbin is independent of the actual
velocities of the flyer and bobbin, both of which are of
course rapidly rotating in the same direction. Flyer-lead
frames were formerly very popular, but are not used to a
great extent at the present time.
3. There is another method of winding the roving on
to the bobbin in which the bobbin rotates at a speed just
sufficiently in excess of that of the flyer to cause it to
wind on the roving as fast as it is delivered by the draw-
ing rolls. This is the arrangement that is almost always
adopted on modern fly frames, and since in this case the
bobbin rotates faster, or leads the flyer, it is known as the
bobbin-lead viethod, fly frames thus equipped being known
as bobbin-lead {tames. Fig. 17 shows the position assumed
by the bobbin, flyer, and roving in a bobbin-lead fly frame.
The front rolls always deliver a uniform length of roving
in any given length of time, and for the purpose of illus-
tration it may also be assumed in this case that the length
delivered in a given period of time is 6 inches. Then, in
order to wind this length of roving on to the bobbin in
a bobbin-lead frame, a point on the surface of the bobbin
must move just 6 inches farther than the eye of the flyer
presser during the length of time that it takes for the draw-
ing rolls to deliver 6 inches of roving. This gain, or
lead, of the bobbin over the flyer is independent of the
actual velocities of the bobbin and flyer, both of which are
of course rotating rapidly in the same direction, as was the
case in the flyer-lead frame, only in this case the bobbin has
the greater speed. *
20 FLY FRAMES §24
13. In both flyer-lead and bobbin-lead fly frames, the
speed of the delivery of the roving and the speed of the
flyers are constant. This is necessary, because if the speed
of the drawing rolls were made variable the production of
the frame would be altered, and also because, in order to
produce an even roving, the sliver should be drawn at a
regular and uniform speed. A variable speed of the flyers is
impracticable, because this would produce a variation in the
amount of twist in the roving. In order, therefore, to com-
pensate for the constantly increasing diameter of the bobbin,
a variation must be made in its speed, so that the tension on
the roving during the winding will be the same whether the
bobbin is empty or full. If the bobbin did not increase in
diameter as it filled with roving, the speeds of the flyer and
bobbin could be easily regulated so that the exact amount of
roving delivered would be taken up. The conditions are
more difficult than this, however, because one revolution of
a full bobbin requires a much greater length of roving to
make one turn around the bobbin than does one revolution
of an empty bobbin; in other words, the circumferential speed
of the bobbin must be the same, no matter what its diameter
is, whether full, empty, or in any intermediate condition.
For example, suppose that the diameter of an empty bobbin
is 2 inches and of a full one 4 inches; then in the first case
only 2 X 3.1416 = 6.2832 inches of roving will be required
to make one turn around the bobbin, while in the latter case
4 X 3.1416 = 12.5664 inches will be required to accomplish
the same result. Thus, as the length of roving delivered is
a constant quantity, and as the difference in the circumferen-
tial speed of the bobbin and of the flyer must also be constant,
the speed of the bobbin must be constantly varied as the
winding progresses.
In a flyer-lead frame, since the flyer rotates at a speed
greater than that of the bobbin, the latter must have its
slowest speed when empty and its greatest speed when
filled, and must constantly and uniformly increase in the
number of revolutions per minute between these two
extremes. This is the principal objection to a flyer-lead
§24 FLY FRAMES 21
frame — the larger and heavier the bobbins become, the
faster they must be driven, hence the greater the amount
of power required to drive the machine.
In a bobbin-lead frame, however, since the speed of the
bobbin is greater than that of the flyer the bobbin must
rotate at its greatest speed when empty and at its slowest
speed when full, and must constantly and uniformly decrease
in the number of revolutions per minute between these two
points. For this reason the bobbin-lead frame is preferred
to the flyer-lead, since in this case as the bobbins grow
large and heavy, it is not necessary to drive them so fast, and
the consumption of power is therefore more uniform.
Although the mechanism for producing this variable speed
of the bobbins is described later, it will be of advantage to
note that with the introduction of cones it is possible, by
making use of suitable gearing, to alter the speed of the
bobbins.
14. Traverse of Bobbins. — It will be remembered
that the lower end of the bolsters, the bolster rail, the bobbin
shafts, and the toothed portion of the bobbin gears are com-
pletely enclosed. These parts combined form what is known
as the carriage, which is given a vertical reciprocating
motion in order to give the necessary traverse to the bobbins.
As the bobbins are placed over the bolsters and rest on the
bobbin gears, which form a part of the carriage, they receive
a vertical reciprocating motion in addition to their rotary
axial motion received from the bobbin gears. As the flyer
eye continues to revolve in one plane during this traverse of
the bobbin, the spindle rail being stationary, the roving is
wound on the bobbin in coils, which vary in pitch according
to the velocity of the vertical movement of the bobbin.
Fig. 3 illustrates one method of imparting the vertical
motion to the carriage. The legs r support the various parts
of the frame, their number varying according to the length of
the frame. These legs are known as sampsons, and have on
one face a groove in which a portion of a rack r, slides. As
the rack r, has an up-and-down motion, the groove in the
22 FLY FRAMES §24
Sampson serves to steady and guide it in order that it may
mesh properly with the gear r^ setscrewed to the shaft ^3,
which extends the entire length of the frame. The racks
are connected to the carriage by means of arms r* securely
bolted to the bolster rail s. As the gear f\ revolves first in
one direction and then in the other, the carriage is given a
vertical reciprocating motion for a certain distance, which is
regulated by the period of rotation of the gear i\ in either
direction. In addition to 'the steadying of the carriage by
the racks, there is a slide connection between the head and
foot Sampsons and the corresponding ends of the bolster rail
that helps to steady and guide it, and if properly adjusted
insures a free and perfect motion of the carriage. As the
carriage has considerable weight, it is balanced by suitable
mechanism, the usual method being to hang weights by
means of chains at each sampson. Referring to Fig. 3, the
weight t is supported by means of a chain /, attached to a
bracket, the chain passing around a pulley r\ attached to the
rack r, and also over pulleys /a, t^ attached to the sampson;
the weight is arranged to balance the rail when the bobbins
are half full.
Another method of balancing the carriage is shown in
Fig. 18. Weights t are suspended from a chain /, that
passes around pulleys t^, t^ and is attached to a drum r^
on the shaft re, which carries a gear meshing with teeth in
the lever r^. The forward end of this lever bears directly
against the under side of a small pulley carried by a bracket 5,
that is attached to the bolster rail s. This method prevents
any possibility of the racks binding in the slides, which some-
times happens with the other method, unless a great deal of
care is taken with the racks and slides.
The latest method of overcoming the weight of the car-
riage and bobbins is by means of a self-balanced carriage.
With this motion the carriage is divided at the center of its
length into two equal parts, and when one section is descend-
ing the other is ascending; consequently, one section counter-
balances the other. The carriage is supported and guided
by means of racks and pinions, as shown in Fig. 3, with the
24
FLY FRAMES
23
exception of the weights. The racks r. for one section of
the carriage face in the direction shown in Fig. 3, while the
Fig. 18
racks for the other section face in the opposite direction;
consequently, as the back shaft r, revolves, one section of
24 FLY FRAMES §24
the carriage will ascend and the other descend, thereby bal-
ancing each other.
Since the carriage is divided into two parts, it is necessary
to use a second mechanism in order to drive the bobbins of
the second section. This mechanism is situated in about
the center of the frame and is driven from the first by
means of a long shaft that extends from the head of the
frame to the second section. This shaft carries a gear at
the head end that is driven from a gear placed on the
sleeve between the gears h^, h^, Fig. 19. At the opposite
end of this shaft is a gear that drives the second mechanism
by means of a carrier gear. By adopting this last method,
the carriage is accurately balanced at all times during the
building of the bobbins, while with the other motions the
carriage is only accurately balanced when the bobbins are
half full.
The description of the method of reversing the direction of
motion of the gear t\, Fig. 3, and the different mechanical
arrangements that are necessary in order to allow the car-
riage to rise and fall and still have the driving arrangement
of the bobbin shafts intact, will be given in detail later.
GEARING
15. Method of Driving the Dra^wing Rolls. — Fig. 19
gives a diagrammatic view of the gearing for a slubber.
The parts are not in all cases shown in the exact position
that they occupy in the frame, since the method of gearing
could not then be clearly indicated. On the shaft m, which is
known as the jack-shaft and is the main driving shaft of the
frame, are placed the tight-and-loose pulleys Wi, Wj, respect-
ively, which are driven either from the line shaft of the room
or from a countershaft belted to the line shaft. On the end
of the jack-shaft m is a gear w,, known as the t%vist gear,
which through the intermediate gear w* and gear^z, drives the
top cone shaft n. This shaft carries at the head, or driving,
end a gear n^ that drives a gear / on the bottom front roll /,.
The method of driving the two back rolls from the front roll
is shown in Fig. 19.
tnp 9T
26 FLY FRAMES §24
16. Method of Driving the Spindles. — On the end of
the jack-shaft that carries the tight-and-loose pulleys is a
gear vi^ that, through an intermediate, or carrier gear, w„
drives a gear p^ that is on the spindle shaft p. Gears on
this shaft similar to p.^ drive the gears j^ that are setscrewed
to the spindles j. It will be remembered that there are two
rows of spindles in all fly frames; consequently, there must
be two spindle shafts similar to p. Only one shaft is shown
in Fig. 19, as the two shafts are placed one directly behind
the other. The one shown is the back spindle shaft, which
always receives its motion direct from the jack-shaft of the
frame. Gearing with the gear /, is a gear on the end of the
front spindle shaft by which this shaft receives its motion.
An important point to be noted in this connection is that
since the gear on one shaft is driven directly by a gear on the
other shaft without the use of any intermediate gear, the two
spindle shafts must revolve in opposite directions. If with
this arrangement the gears on each spindle shaft were con-
nected to the gears on the spindles that they drive in exactly
the same manner, the two rows of spindles would revolve in
opposite directions. In order to overcome this difficulty the
gears on one spindle shaft are placed on one side of the gears
on the spindles that they drive, while the gears on the other
spindle shaft are placed on the opposite side of the gears
on the spindles that they drive, as shown in Fig. 13.
17. Metliod of Driving the Bobbins. — Referring
again to Fig. 19, it will be noticed that a gear m-, is set-
screwed to the jack-shaft. This gear through the gears h,, h„
drives the gear h^, which is setscrewed to a sleeve that is
loose on the jack-shaft. This sleeve carries another gear //s,
which through a carrier gear //» drives the gear h^, on the
back bobbin shaft L.. The bobbin shaft carries bevel gears //,
that drive the bobbin gears /;,. These bobbin gears are
illustrated in Fig. 12 and carry a flange, a projection of
which engages with a slot in the bottom of the bobbin and
thus causes the bobbin to revolve with the bobbin gear. A
gear on the front bobbin shaft is driven directly from the
§24 FLY FRAMES 27
gear Z/,, Fig. 19, on the back bobbin shaft, and since these
shafts revolve in opposite directions, it is necessary, in order
to have all the bobbins revolve in the same direction, to place
the gears on one bobbin shaft on one side of the bobbin
gears that they drive, while the gears on the other bobbin
shaft must be placed on the opposite side of the bobbin gears
that they drive. This arrangement is also shown in Fig. 13.
DIMENSIONS OF FLY FRAMES
18. Fly frames are spoken of not only according to the
name of each kind of frame, but also by the number of
spindles, the length of the bobbin that the first layer of roving
covers (known as the traverse of the bobbin), and the diam-
eter of the full bobbin. Thus, a frame spoken of as a
96-spindle 9 in. X ^\ in. indicates that the frame has two
rows of spindles, 48 in each row; that the greatest possible
traverse on the bobbin is 9 inches in length; and that when
the bobbin is full it cannot exceed 41 inches in diameter.
The traverse of a bobbin used on slubbers is usually from 10
to 12 inches; on first intermediates, from 8 to 10 inches; on
second intermediates, from 7 to 8 inches; and on roving
frames, from 5 to 6 inches. The reason for this gradual
reduction in the traverse of the bobbin is that as the roving
becomes reduced in size it is necessary to wind it on a
smaller bobbin, so that the bobbin will not be too large to
be pulled around by the roving when placed in the creel of
the succeeding machine.
The diameter of the full bobbin that can be made depends
on the distance between the spindles, which is so arranged
as not to make too large a bobbin, for the same reason
as that given above. In most cases the diameter of the full
bobbin is one-half the length of the traverse; for example, a
12-inch traverse frame makes a 6-inch bobbin, usually written
12 X 6. Other sizes are referred to as 10 X 5, 9 X 4i,
8x4, 7 X Si, 6x3, etc. There are exceptions to this rule
in very fine frames, where the bobbin is often made smaller in
diameter, as, for example, a 6 X 22 frame. In this connection
28
FLY FRAMES
24
it should be noted that the diameter of a full bobbin made
on a fly frame is not equal to the space between two spindles
in the same row. For example, on a 12 X 6 frame the
space between the spindles in the same row is 10 inches,
although the diameter of the full bobbin is only 6 inches.
This allows sufficient space for clearance of the flyers while
revolving.
The following table gives the standard sizes of frames
as made by one machine builder:
TABLE I
Frame
Slubber . .
Slubber . .
Slubber . ,
Slubber . ,
Slubber . ,
First intermediate
First intermediate
First intermediate
First intermediate
First intermediate
First intermediate
First intermediate
Second intermediate
Second intermediate
Second intermediate
Second intermediate
Second intermediate
Second intermediate
Roving
Roving
Roving
Size
Inches
12 X
12 X
II X
10 X
9X
10 X
10 X
9X
9X
8X
8X
8X
8X
7 X
7 X
7 X
7X
6X
6X
5 X
4iX
6
6
5*
5
4*
5
5
4i
4i
4
4
4
3i
3i
3^
3
3
3
2i
2i
2i
Space
Between
Spindles
Inches
ID
9i
9
9
7i
8
7i
7
6i
6
si
5i
sl
5
4i
4i
4i
4i
4i
4
Number of
Spindles
24 to 68
24 to 68
28 to 72
32 to 76
30 to 96
40 to 104
42 to 108
48 to 114
48 to 1 14
48 to 136
48 to 136
66 to 132
56 to 144
64 to 152
64 to 152
72 to 160
72 to 160
80 to 168
88 to 176
96 to 184
I 12 to 200
§24
FLY FRAMES
29
Fly frames are not usually constructed over 36 feet in
length, as the torsion on the rolls and shafts would be
excessive if this length were increased to any g-reat extent.
The modern tendency is to use frames of about this length,
and Table I is prepared on this basis.
The main driving pulley, or the pulley on the jack-shaft,
of the frame is usually about 16 inches in diameter with a
2-inch face, although pulleys are used that range from 12 to
16 inches in diameter, with faces from li to 2i inches in
width.
The weights of the frames vary considerably according
to the make, the number of spindles, and the gauge; a
72-spindle slubber will weigh about 7,800 pounds; a 120-spin-
dle first intermediate will weigh about 10,750 pounds; a
144-spindle second intermediate, about 9,250 pounds; and a
200-spindle roving frame, about 9,780 pounds.
The horsepower required to drive a frame varies con-
siderably; therefore, no table can be given that will be accu-
rate under all conditions, as various matters affect the amount
of power required. The following table may be used as a
guide to determine the amount of horsepower required.
TABIiE II
Frame
Gauge
Inch
Spindles per Horsepower
Slubber
First intermediate .
Second intermediate
Roving
9
7
si
4i
35
6o
75
95
FLY FRAMES
(PART 2)
PRINCIPAL MOTIONS OF FLY FRAMES
MECHANISMS FOR CONTROI^I^ING SPEED
OF BOBBINS
DIFFERENTIAL, MOTIONS
NoTK. — In this Section the bobbin-lead type of fly frames will be
dealt with exclusively.
1. Introductoi'y. — In order to wind the roving on the
bobbin it is necessary that the excess circumferential speed
of the bobbin over the flyer shall be equal to the circumferen-
tial speed of the front roll, so as to take up the roving as fast
as it is delivered by the front roll. If the bobbin made the
same number of revolutions per minute continually, it would
gradually strain and break the roving as the bobbin increased
in diameter; therefore, some arrangement must be adopted
by which the number of revolutions per minute of the bobbin
may be gradually reduced as the bobbin grows larger. The
speed of the bobbin is regulated and controlled by two
mechanisms that act in combination. One is known as the
ditferential motioyi, more commonly called the compo^ind in
America, while the other consists of two cones and connec-
tions. The object is to provide a ready means of automat-
ically reducing the number of revolutions per minute of the
bobbin in exact proportion to the increase in its diameter.
For notice of copyright, see Page immediately following the title page
225
SSI G 15
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LJ=i
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?^§ © Ecmnr
§25 FLY FRAMES 3
2. Referring to Fig, 1, the gear in., on the jack-shaft
drives the bobbins, its motion being imparted through the
gears 7^, h» to the gear //s, which is on a sleeve with h^. The
gear h^ drives the bobbin shaft h through the gears lu, h^,
the bobbin receiving motion from this shaft by means of the
gear //, and bobbin gear h^. The speed of the gear m., is con-
stant, but by a peculiar arrangement of the gears //«, h,, //«, //«
it is possible to alter the speed of the gear h^ independently
of ?«,; this in turn alters the speed of the gear //s and con-
sequently that of the bobbins. This alteration in the speed
of the gear /;« is obtained by imparting motion to the gear h^
by an entirely independent mechanism. Dealing first with the
method of driving the gear h», it will be noticed that the top
cone shaft w carries a cone «» that, by means of a belt ii^,
drives a bottom cone 7i^. At the beginning of a set, that is,
when the first layer of roving is being wound on the bobbins,
the cone belt is at the large end of the top cone and at the
small end of the bottom cone, but as the bobbins gradually
grow larger the belt is moved along the cones, until at the
finish of a set, that is, when the bobbins are full, the belt is at
the small end of the top cone and the large end of the bottom
cone. As the top cone is the driver, any parts receiving
motion from the bottom cone will have their highest speed
at the beginning of a set and their lowest speed at the finish.
The manner in which the cone belt is moved along the cones
as the bobbins are built will be fully explained later.
Referring again to Fig. 1, it will be noticed that a gear on
the end of the bottom-cone shaft drives, through suitable
gearing, the gear ««, which meshes with the gear h,; conse-
quently, as the belt is moved from the small to the large end
of the bottom cone, or, in other words, as the bobbins become
full, the speed of the gear We and therefore that of the gear //«
will be lessened. The gears //e, //,, //«, h^, vi^ form the coni-
pouiid, or differential motion, and in order that the effect
of lessening the speed of the gear «« may be fully under-
stood, reference will now be made to Fig. 2, which is a view
of the compound alone. The large gear //» is known as
the Sim gear and supports the two bevel gears //,, hy, by means
FLY FRAMES
§25
of studs on which these
gears work loosely, as
shown in Fig. 2 {b).
Thus, if the gear h^ re-
volves it carries with
it the two bevel gears
h,, hg, which at the
same time are free to
revolve on the studs
on which they are
mounted. The action
of these gears is as
follows: The gear m,
being fixed to the jack-
shaft 7?i drives the
gear //« through the in-
termediate gears //,, h^.
The gear h, performs
the same work as h^
and for present con-
sideration may be
imagined as not exist-
ing, being used merely
to balance h^ and cause
the whole arrangement
to revolve more uni-
formly. The gears
m-,, he are of the same
size, and consequently
if h» were held still, or
prevented from revol-
ving, 7)1 ^ would drive he
at the same speed as
the shaft in, but in the
opposite direction. If,
however, //« is made to
revolve in the same di-
rection as he, the latter
§25 FLY FRAMES 5
makes not only the number of revolutions that it derives
through being driven by w,, but an additional number of
revolutions caused by the acceleration that h^ gives it.
3. One not acquainted with mechanics may be surprised
that h^ causes h^ to be accelerated 2 revolutions for each
revolution that //g makes. Since, however, this is a well-
known fact, no mathematical proof will be given, but if the
privilege of experimenting with a compound in a mill can be
obtained it can easily be proved that by holding m^ still and
turning h^ around once //« will revolve twice. Another test
may be made with an ordinary yarn wrapping reel, in which
a similar contrivance is used. It will be found that the reel
makes two revolutions when the handle is turned once,
although each of the gears that form the compound has
the same number of teeth; the handle of the reel acts the
same as gear he,. Fig. 2.
To take an actual example, suppose that the jack-shaft ni
makes 400 revolutions per minute. If lu is held still, Ju will
make just 400 revolutions per minute, but in the opposite
direction to w,. Supposing that h^ is now caused to revolve
20 times per minute in the same direction as //«, it will be
found that h^ makes 440 revolutions per minute, since
400 + (20 X 2) = 440. Suppose that without stopping the
frame, the number of revolutions of h^ is automatically
reduced to 15; then it will be found that lu makes 430 revolu-
tions; thus, 400 -t- (15 X 2) = 430. Suppose, again, that the
speed of h^ is decreased to 10 revolutions per minute; then //«
will make 420 revolutions, but always in the opposite direc-
tion to m,\ thus, 400 + (10 X 2) = 420. If the train of gears
between the gear Ju and the bobbins is so arranged that the
bobbins make 1\ times as many revolutions as the gear //s,
which is on the same sleeve as Ju, then in the first case the
bobbins will make 440 x 2^^ = 1,100 revolutions, while in the
last case they will make 1,050 revolutions, so that it will be
seen that their speed has been automatically reduced from
1,100 to 1,050 revolutions per minute as the bobbin has
increased in size.
6 FLY FRAMES §25
It will thus be seen that this arrangement provides the
varying conditions necessary for the building of a bobbin.
When the roving is being wound on an empty bobbin, the
latter must be rotated at its highest speed in order to wind
on the roving delivered; this speed is attained by having the
cone belt at the large end of the driving cone and the small
end of the driven cone. As the roving is wound on the bobbin
and the bobbin increases in size, a gradual reduction of the
speed of the bobbin is required, so that it may revolve at its
slowest speed when the bobbin is full. By this time the cone
belt has been moved along the cones until the small end of the
driving cone is driving the large end of the driven cone. As
the speed of the driven cone gradually diminishes, that of the
gear n^ decreases also, since it is driven from the bottom cone.
Consequently, the gear h^ will be driven more slowly, as well
as the' gear //e and the gears that drive the bobbins, since
these are driven from the gear h^, which is on the same
sleeve as the gear h^.
4. The compound just described is an old type and is
found on most of the older frames. The one great objection
to it is the unnecessary strain on the cone belt on account of
the friction caused by the sleeve that carries the gears ^e, h^,
and also the one that carries the sun gear h^. These sleeves
and gears revolve in an opposite direction to that of the jack-
shaft m. The compounds shown in Figs. 3, 4, and 5 are built
to avoid this fault and are so constructed that all parts revolve
in the same direction. Although these styles differ in construc-
tion, they all have the same objects in general; that is, they are
all constructed to drive the bobbins at a varying speed in
order to effect winding, and in the last three types are con-
structed to reduce the strain on the cone belt by reducing the
amount of friction and thereby reducing the liability of its
breaking. The amount of oil consumed is also reduced to a
minimum. As far as possible, the parts in Figs. 2, 3, 4, and 5
that perform similar work have the same reference letters.
Fig. 3 shows a compound that is peculiar in construction
but very simple and accurate in its workings. On the main
§25
FLY FRAMES
shaft in is a boss, or
cross-piece, q for the
reception of, and to
form a bearing for, the
small cross-shaft q^ that
carries the two bevel
gears h-,, h». Loose on
the shaft vi is a bell,
or, as it is sometimes
called, socket, gear //j,
which through its con-
nections drives the
bobbins. Attached to
the gear h^ is a bevel
gear h^. Beyond the
cross-shaft and fast on
a sleeve is the gear h^,
which is driven from
the bottom cone by a
train of gears. On the
opposite end of this
sleeve, which is loose
on the shaft vi, is a
bevel gear m^ that
meshes with the larger
bevel gear h^. The
shaft m being posi-
tively driven at a con-
stant speed, imparts
motion to the bell
gear 7^5, since the cross-
shaft q^ and the parts
connected with it turn
the bevel gear h^ of
which hs is a part, and if
it were not for the ad-
ditional speed imparted
through the gear h^.
rrrx
8 FLY FRAMES §25
the gear //s would make the same number of revolutions as m;
ht, however, is positively driven in the same direction as r?i
through the cones, while w,, being on the same sleeve with h^,
drives h^ and consequently //, on the other end of the cross-
shaft. As h, meshes with //«, the latter and also h^ receive
an accelerated motion in addition to that derived through the
motion of the shaft 7n.
The effect of the combined forces acting on h^ is to cause
it to revolve at such an accelerated speed that, when winding
is being performed at the beginning of a set of bobbins, the
empty bobbins revolve so much faster than the spindles as
to wind on the roving delivered by the rolls. As the
gear h^ is driven from the bottom cone and the speed of this
cone is reduced in the usual manner, the speed of h^ is
gradually reduced as the bobbins are built up, resulting in
the diminishing of the speed of h^ and /u; the speed of these
gears, however, is not reduced at any time so as to be
less than the speed of the shaft ?n, thus always insuring that
the bobbins revolve faster than the spindles and that winding
is constantly taking place.
In this compoiind, all the gears that are loose on the
shaft m revolve in the same direction as the shaft; thus, the
power required to drive them is greatly reduced in compar-
ison with the old-style compound, since there is only a very
slight amount of friction between the gears and the shaft.
An advantage over the older form of compound will be
readily seen in the saving of power and the lessening of the
strain on the working parts, especially on the cone belt,
where the strain is lessened to a very great degree. In this
compound, the revolution of the shaft in becomes a help to
the cone belt instead of an obstacle, as in the old form of
compound. The greatest strain put on the belt is no more
than is required to revolve the bobbins at their maximum
speed of about 100 revolutions per minute beyond those run
by the spindles. The shaft helps to the extent of the num-
ber of revolutions that it drives the spindles, and the balance,
which varies from 100 revolutions to none, is easily obtained
with little strain on the cone belt. It is obvious that with
§25
FLY FRAMES
the strain thus reduced, the cone belt will almost entirely
cease to be a trouble or the cause of bad work.
5. Fig. 4 (a) and (d) shows views of a compound widely
different from those described. It uses spur gears instead
of bevel gears, thus reducing the amount of friction. The
gear ka is on a sleeve that carries at its opposite end a
gear m,; this sleeve is loose on the jack-shaft m and revolves
in the same direction. The gear /i» is driven by the cones
in the usual manner, its speed depending on the position of
the belt on the cones, while the gear ;//, causes the gears /i,, //«
to revolve on their axes. The annular gear /le, which is
fast to the jack-shaft m and revolves with it, gives motion
to the disk k,o simply because the gears /i,, /is, which are
on studs fastened to the disk, mesh with its teeth. The
gears //,, /is have two motions; they revolve on their axes and
also around the annular gear k^. Thus, the disk //,o is caused
10 FLY FRAMES §25
to revolve at a greater speed than the jack-shaft, and as
it is on the same sleeve as the gear //s, it causes h^ to
revolve and give motion to the bobbins. When the speed of
the gear h^ is reduced by the cones, it reduces the speed of
the gear ;;^,, and consequently that of the gears h.,, hg, as well
as that of the gear h^, thus driving the bobbins more slowly.
The sleeve that carries the gear hs and the disk //lo is outside
of the one that carries the gears h^, m,, but it revolves in the
same direction; thus there is a sleeve within a sleeve, form-
ing what might be called a double, or compound, sleeve. The
gearing in this compound is protected from dust and dirt by
a shell or casing, which also forms an oil chamber so that
the gears and sleeves are well lubricated at all times.
Fig. 4 {a) shows the compound closed and in working posi-
tion, while Fig. 4 ((5) shows it open with the internal parts
exposed to viev^^.
6. A compound that is novel, compact, and very effective
is shown in Fig. 5 (<?) and {b); («) is a plan view partly in
section, while {b) is a sectional elevation. The jack-shaft m
carries the twist gear m^ and the spindle gear vi^, while the
compound is situated between these two gears. Loose on
the jack-shaft is a sleeve carrying the gear h^ and the
cam //lo. The cam is circular and has a beveled face, as
shown in the elevation {b) . Inside the shell, or bell, por-
tion of the cam is the bevel gear m-, fast to the jack-shaft in.
Bearing against the face of the cam h-,a is a circular disk q^
that revolves freely on a spherical bearing q^. This disk
has 36 teeth on each side, as shown at ^3 and q^; ^3 meshes
with m.,, which has 32 teeth, while q^ meshes with the bevel
gear h^, which has 36 teeth and is fastened to a long sleeve
that is loose on the jack-shaft and carries the spherical bear-
ing ^5 and the gear h^ that drives the bobbins. As the jack-
shaft revolves, it carries the bevel gear in., with it; and as m.,
meshes with q^, it causes the circular disk to revolve on the
spherical bearing. Since q^ forms a part of the circular disk,
it will revolve with the disk and impart motion to the bevel
gear //« and the bobbin gear h^, because q^ meshes with h^.
25
FLY FRAMES
11
12 FLY FRAMES §25
At the beginning of a new set of bobbins, the bobbin
gear Ju makes the same number of revolutions per minute
as the jack-shaft, and drives the bobbins at the required speed
to wind on the correct amount of roving. As the gear //,
is driven from the cones, it is the only medium for altering
the speed of the bobbins. When commencing to wind a new
set of bobbins, this gear makes the same number of revolu-
tions per minute as the jack-shaft; consequently, for the
present the cam may be considered as not existing, as it
maintains the same relation between the gears m-,, ^3, q*, h^,
thus allowing them to act as clutch gears, because the same
teeth of the gears mesh with each other for the time being,
and cause h^ to make the same number of revolutions as the
jack-shaft.
At the completion of each layer of roving on the bobbins,
the cone belt is moved along the cones, thereby decreasing
the speed of the gear h^ and the cam //i„. As the speed of the
cam is decreased, it causes the circular disk to oscillate on
the spherical bearing and change the points of contact of the
gear m., with ^3, and q^ with h^. This oscillating motion of
the disk causes q^ to roll around the gear w„ and as m., is
smaller than q^, it causes a direct loss of speed to the
circular disk, because it requires more than one revolution
of the gear w, to give ^3 one complete turn. Since the
speed of the disk is reduced, the gears Ju, h^ are affected in
a similar manner, which causes the bobbins to make fewer
revolutions per minute. The gradual reduction in the speed
of the bobbins in a bobbin-lead frame is necessary in order
that the bobbins may retain their proper circumferential
speed, as their diameters increase with each new layer of
roving.
This entire motion is protected by a shell, or casing, 21 and
may be thoroughly oiled by means of the oil hole 7^, which
extends through the boss of the casing and the sleeve of the
spherical bearing to the jack-shaft, and there connects with
a passage in the sleeve of the spherical bearing. This pas-
sage ends at a chamber u., that is in the spherical bearing.
A hole in the bearing allows the oil to be distributed on the
§25 FLY FRAMES 13
face of the bearing and to pass into the large chamber, where
it is distributed by the projections u^ on all of the remaining
parts, thus insuring a perfect lubrication at all times.
THE CONES
7. Any one of the four types of compounds described
provides a method of controlling the speed of the bobbins
and gradually reducing it as they increase in diameter, if the
speed of the controlling gear of the compound itself is suit-
ably reduced. The action of the compounds shown in
Figs. 2, 3, 4, and 5 is governed by the gears lettered h^ in
each case. If in any one of these compounds the speed of
this gear is reduced, the speed of the bobbins is reduced.
To secure the suitable reduction of the speed of the control-
ling gear in compounds on fly frames, a pair of cones is
always introduced between the source of power applied to
the machine and the compounds. These cones as used in
combination with the ordinary type of compound are shown
in Fig. 1; the top cone n^ is concave and has a diameter of
62 inches at one end and 3i at the other, while the lower
cone is convex and has a diameter of 6i inches at the large
end and 3i at the small end. These cones are connected by
a belt, by which the upper cone drives the lower cone; this
belt is gradually moved from the larger end of the top cone
to the smaller end during the filling of the bobbin, a slight
movement being given to it each time that the traverse of
the frame is changed. This movement is so proportioned
as to bring the cone belt to the small end of the upper cone
by the time the bobbins are filled.
As the length of roving wound on the bobbin always
equals the excess surface speed of the bobbin over the flyer,
if a bobbin starts with a certain number of revolutions per
minute, its rotary movement in excess of that of the flyer
must be decreased in direct proportion to its increase in
diameter. If the diameter of the full bobbin is four times
that of the empty one, which is common in fly frames, the
excess speed must be reduced to one-quarter. For instance,
14 FLY FRAMES §25
if the empty bobbin is 1 inch in diameter and the full bobbin
4 inches in diameter, this means that the diameters of the
cones must be arranged to give a reduction of 4 from one
extreme to the other. The diameters suitable for this and
such as are generally adopted are those mentioned, and it is
obvious that the lower cone will revolve four times as fast
when driven from the large end of the upper cone as it will
when driven from the small end; thus, 62 -^ Si = 2; Si -^ 62
= .5; 2 -- .5 = 4.
Formerly cones were made with a straight surface, dimin-
ishing equally from the large to the smaller end of the cone,
but it has been found in practice that a concave upper cone
and a convex bottom cone give more even winding, and they
are now usually so constructed. When the belt is on the
large end of the top cone and driving the small end of the
bottom cone, the roving is being wound on the bare bobbin.
_ BUILDER MOTIONS
8. There are several very important points that should
be considered in connection with the winding of the roving
on the bobbin. It is customary to have each succeeding
layer of roving slightly shorter than the preceding one, thus
forming a taper at both ends of the bobbin. Thus, as is
shown in Fig. 6, the first layer of roving that is placed on the
bobbin extends from a to b, while the last la^^er extends only
from c to d. Consequently, it becomes necessary to intro-
duce some mechanism by means of which the traverse of the
carriage may be shortened each time one complete layer of
roving has been placed on the bobbin. It might naturally be
supposed that since the traverse is shortened as the bobbin
grows larger, the time occupied by the carriage in making
the traverse will be lessened; but this is not so, since with
each layer of roving the diameter of the bobbin is increased
and consequently, although the part of the bobbin that is
covered by the layer is less, there is actually a greater length
of roving. Still another point to be noted is that in order to
make a well-wound bobbin it is necessary that there should
§25
FLY FRAMES
15
be only a slight space between any two adjacent coils in the
same layer of roving, and that this space should be main-
tained throughout the building of the bobbin. It will be
seen that the distance between two adjacent coils of roving
will depend on the speed at which the bobbin is traversed.
It would be a comparatively simple matter to so regulate
the speed of the carriage that the roving would be wound
correctly for one layer, but the principal difficulty in building
the bobbin lies in the fact that the correct speed of the car-
riage for an empty bobbin is not the correct speed for the
bobbin after it has had several layers of
roving wound on it. That this is so may
be readily seen if it is considered that
with each additional layer of roving the
bobbin is increased slightly in diameter
and that consequently it takes a greater
length of roving to form one complete
coil around the bobbin. Therefore, in
order that the same space may exist
between two consecutive coils in any
layer throughout the filling of the bob-
bin, the speed at which the carriage, and
consequently the bobbin, traverses up
and down must be lessened as the
bobbin becomes larger.
Referring again to Fig. 1, the shaft n.,,
which is driven from the bottom cone,
carries a bevel gear n^ that drives the
bevel gear n^ on an upright shaft.
\'.— .. ' 1/a
LUi:
Fig. 6
At the lower end of this
upright shaft is a bevel gear v that by means of the gears v^, v,,
the action of which will be explained later, gives motion to
the shaft v^. The gear lu on the end of this shaft drives,
through suitable gearing, the shaft r,, which carries the
gear r, that imparts motion to the rack r,. Since the motion
of this train of gears is derived from the bottom cone, the
rack and, consequently, the carriage will be driven at a speed
that is uniformly decreasing as the bobbins are becoming full,
which is the result desired.
16 FLY FRAMES §25
AMERICAN TYPE OF BUILDER
9. In order to shorten the length of the traverse with
each layer of roving placed on the bobbin and also to reverse
the direction of the traverse, the builder motion is applied
to all fly frames. A view of a builder motion that illustrates
the style generally used on American-built frames is given
in Figs. 1 and 7. Its parts are as follows: Attached to the
carriage, and consequently rising and falling together with it,
is a bracket x, Fig. 7, carrying a casting that supports a central
shaft Xi on which right- and left-hand threads are cut. The
upper thread carries the jaw x^, and the lower thread the
jaw x,; therefore, by turning the shaft x, in the proper direc-
tion the two jaws can be brought closer together, the upper
jaw X2 projecting beyond the lower jaw .1-3 and being capable
of sliding outside, as shown in the illustrations. The upper
part of the shaft Xi is made square and projects through a
gear Xt supported by a bracket. As the gear x^ is not set-
screwed to the shaft x^, any vertical movement of one will
not affect the other, and yet on account of that part of the shaft
that projects through the gear being square, and the aperture
in the gear being of such a shape as to fit the shaft, any rotary
motion of one will be communicated to the other. In study-
ing this motion it should be understood that as the bracket x is
raised and lowered by the carriage it takes with it the shaft Xi
and the jaws x^, X3. Another upright shaft w, known as the
tumbler shaft, carries a dog 7e\ having two arms w^, w^. At
the bottom of the tumbler shaft is a circular disk y^ with two
lugs, shown in plan in Fig. 7 (b), against each of which, in
turn, a lever y, is pressed by means of a strong spring in such
a manner as to tend to move the shaft a small portion of a
revolution. At the upper end of the shaft is a gear w^ com-
posed of four sections, also shown in plan in Fig. 1 (d); two
of these sections that are directly opposite each other have
13 teeth each, while the other two sections are blank.
10. The action of this part of the mechanism is as follows:
Suppose that the parts are in the position shown in Fig. 7; then
§25
FLY FRAMES
17
the spring acting on one of the lugs on the disk at the foot
of the shaft w is tending to give this shaft a partial revolu-
FiG. 7
tion but is prevented from doing so by the arm w^ bearing
against the jaw x,. The carriage when the parts are in this
18 FLY FRAMES §25
position is moving up, and when it has risen sufficiently so
that the jaw x^ is raised above the arm w^, the spring is
allowed to act on the shaft u> and turn it until the gear ?i,o on
the end of the top-cone shaft engages with the teeth in one
of the sections of the gear w^. These two gears continue to
engage until a blank section on the gear w^ is presented
to Wio, at which point the spring at the foot of the shaft 7v
will act on the second lug and further turn the shaft until the
arm w^ comes in contact with one of the jaws. The entire
motion of the shaft w at any one time is thus equal to half a
revolution. It should be noted that although the carriage at
the time these actions take place is sufficiently high to allow
the arm w^ to pass under the jaw x,, the arm w^, owing to
its being situated in a higher plane than zfo, will come in
contact with the jaw X3, and as the carriage is lowered, with
the jaw x^ also. When the motion of the carriage is down-
wards, the arm w^ is bearing against the jaws, and as the
jaw Xi is brought low enough to free this arm the shaft w is
given a half revolution in the same manner as that described.
In making this half revolution, the tumbler shaft accom-
plishes a change in three parts of the frame at the same
time: (1) The carriage is driven in an opposite direc-
tion, that is, if it was going up before, it is going down
after the shaft has turned; (2) the belt is moved along the
cones for a short distance; (3) the length of the traverse is
shortened. Dealing with these points separately and in the
order given above, when the tumbler shaft is given a half
revolution it turns the cam )u situated at its lower end, a plan
view of which is shown in Fig. 1 (c). This action results in
giving the rod y, Fig. 1, a longitudinal motion. This rod is
jointed to the rod v^ in such a manner that the latter is
allowed to revolve without in any way affecting the former,
and yet any longitudinal motion of one will affect the other.
On the rod zs are shown two gears z\, v., the teeth of which
face each other; these are known as the twin sjears. They
are so adjusted on the rod that a movement in either
direction of the rod y causes one or the other of the two
gears to come in contact with the bevel gear v. It will be
§25 FLY FRAMES 19
seen that the direction in which the shaft v^ rotates will
be periodically reversed; i. e., if it were turning from right
to left before the tumbler shaft turned, it will be turning from
left to right afterwards. As the carriage is primarily driven
by the shaft v^, the direction of movement of the carriage
will thus be reversed at every turn of the tumbler shaft.
On the tumbler shaft is placed a gear j, that through a suit-
able train drives the gear y^ gearing into the rack j^^, which
carries at one end a belt guide y^, Fig. 1; consequently, as the
tumbler shaft is revolved, the gear y^ will turn j/^, thus giving
motion to the rack y^, and through the belt guide y^ moving
the belt a short distance toward the small end of the top cone.
As the rack is moved, it imparts motion to the gear x^
which through the gear x^ turns the gear x^ and consequently
the shaft x^. The movement of the shaft x^ brings the
jaws x^, Xs closer together, which allows the arms za^y w, to
escape the jaws when the carriage has made a shorter
traverse than was previously necessary.
11. Change Gears. — In connection with this builder
motion there are the following very important change gears,
reference being made to Fig. 1: the lay gear v^, the tension
gear y^, the taper gear x^, and the rack gear y^. The lay
gear v^ forms part of the train of gears that regulate the
speed at which the carriage moves up and down, and con-
sequently the distance between any two consecutive coils of
roving on the bobbin. In case the correct distance is not
maintained between the coils, this gear is the one that is
changed. The tension gear y^ regulates the distance that the
cone belt moves along the cones at each reversal of the
traverse of the carriage, and consequently controls the tension
of the roving between the delivery rolls and the flyer, since if
the belt is moved a shorter distance along the cones, it causes
all the motions controlled by the cone belt to tend toward
winding more quickly and thus increase the tension of the
roving, while on the other hand if the cone belt is moved a
greater distance, the reverse will be true. The taper gear x^
regulates the distance that the jaws of the builder motion will
20 FLY FRAMES §25
be brought toward each other at each reversal of the car-
riage, and consequently regulates the taper on the bobbin.
The rack gear y^ regulates the distance that the rack moves at
any one time, and consequently also regulates both the tension
and the taper at the same time. By changing the rack gear
to a smaller gear the rack is moved a shorter distance, thus
causing the jaws of the builder to come together more
slowly and the belt to be moved along the cones more slowly.
ENGLISH TYPE OF BUILDER
12. Fig. 8 {a) and {b) shows a style of builder motion
that is found on English-built frames. Fig. 8 {a) shows
this motion as it appears on the frame, while Fig. 8 {b)
shows the motion with certain of the parts removed in order
that its action may be more clearly explained. Attached to
the carriage of the fly frame is a bracket x that has a slot x^
cast in it. A stud x^ that works in this slot carries a bar x^,
known as the poker bar, that passes through a cradle a
loose on the shaft b. Attached to the bracket x is an arm y that
has connected to it at y^ a cradle c centered at <:,. It should
be carefully noted that as the carriage traverses up and down
it will carry with it the bracket x and thus cause the poker
bar X3 to give a rocking motion to the cradle a. At the same
time the cradle c will also receive a rocking motion, due to
its being connected to the bracket x by the arm y. A vertical
shaft d carries the two gears y., d^. The gear y. engages
with the rack y^ that carries the belt guide, while the gear d^
engages with the gear d^, which is fastened to the shaft b.
Fastened to the same shaft are the gears e,e^, the gear (?,
engaging with teeth on the under side of the poker
bar X3 while the gear £> is a ratchet gear and has work-
ing in its teeth the stop-pawls ^,,^3. At the top, or head, of
the vertical shaft ^ is a drum d^, on which is wound a chain /
carrying a weight g; this weight exerts a constant pull on
the chain, and were it not for the engagement of the stop-
pawls e.,e^ with the teeth of the ratchet gear <?, would cause
the shaft d to revolve until the chain was entirely unwound
from the drum. The cradle h, which is loose on the shaft b,
1 afo II II II ii
I I i \[p~',\ ii I'll 1
I ! '7 il II I' iij
ii 1.^1 ,1 ii
Ji_lL±!_'i J,
fa)
F.'G. !
(f>)
)2S>
§25 FLY FRAMES 21
carries at its lower end a stud j, and bracket y, which has two
projecting armsy.,/,, while at its upper end the cradle has
three projections //,, h^, h^. The projection /;. forms a shoulder
against which the two pigeon levers k, k^ are kept in contact
by means of the spring k^ that passes under the stud b and is
connected to the levers at k^, /C%, respectively, thus exerting
a continual pull on the levers k, ^, in a downward direction
toward the shaft b. The levers k, k^ are centered on studs k.,, k^
that are secured to the frame. Directly above the points c^, c,
of the cradle c are two hooks m^, m^ that form part of the
rods ;;/, Wi, respectively. The rod w has the weight 7i
attached to its lower end, while at its upper end it passes
through the projection h^ of the cradle h. The rod m^ is
connected to the cradle h in exactly the same manner and
carries the weight ?^,. Consequently, if the weights are not
supported at the points c^, c^ by means of the hooks m„ w,,
they will be suspended from the projections //j, h^.
13. The operation of the parts is as follows: Assuming
that the carriage is ascending, as indicated by the arrow,
carrying with it the poker bar x^ and raising the right-hand
side of the cradle c, as the rail ascends, the point c^ descends
until the rod ;;z with weight n is resting entirely on the end h,
of the cradle h; the weight 7i tends to pull h., downwards but
is prevented from doing so by the lever k being in contact
with the shoulder h^. When the carriage has ascended far
enough, the setscrew a^ that is attached to the cradle a forces
down the lever k at its outer end, thus releasing the shoulder h^
and allowing the cradle h to be pulled over by the weight n,
which as previously stated was hanging from h^, due to the
descent of c. Not only does the ascent of r^ allow the rod rn
attached to the weight 7i to rest on Ii^, but it simultaneously
raises the rod ;«. attached to the weight n^ from the projec-
tion //a, by raising the point r, and allowing the weight to be
borne by the cradle c at this point, thus avoiding any pull of
?ii on hi and also allowing the cradle // to rock freely. The
cradle h carries at its lower extremity the bracket /; there-
fore, if the center of motion is at b, any movement of //a will
22 FLY FRAMES §25
cause the shoulder /?, to swing in a similar direction and thus
transmit to / a like movement, but in an opposite direction.
The downward movement of h^ causes the shoulder //, to
swing to the left, and j to swing to the right. In doing so, the
arm j-, forces the pawl e^ out of contact with the ratchet e and
allows the weight g to rotate the vertical shaft d until the
pawl e^ engages with the ratchet e; since e^ and e^ are connected
by the spring e^, which has a tendency to draw them together,
€., will therefore engage with the ratchet e after it has turned
half a tooth. The rotation of the shaft d will communicate
motion to the rack y^ by means of the gear y,, thus moving the
belt along the cones for a short distance. At the same time,
the gear <?, will move the poker bar slightly to the left, thus
bringing the stud .r, nearer the cradle a; consequently, on the
next traverse the setscrew a^ will force down the lever k^ when
the carriage has moved a shorter distance than on its previous
traverse. Attached to j^ is an arm p that is centered at P-,.
Connected to the lower end of this arm is a rod q that is
jointed to the shaft carrying the twin gears. As j^ is forced
one way or the other by the action of the cradle h, it swings
the arm p, which, acting on the rod q, causes the opposite twin
gear to engage and thus reverses the direction of motion of
the carriage.
METHODS OF DRIVING BOBBIN SHAFTS
14. Horse-Head Motion. — Referring again to Fig. 1, it
will be remembered that the gear //s, which is carried by a
sleeve on the jai:k-shaft m, drives, by means of the inter-
mediate gear //*, the gear h^ on the end of the back bobbin
shaft. An important point to be noted in connection with
this drive is that the jack-shaft, which carries the gear h^,
revolves constantly in the same position, while the gear //,
on the bobbin shaft, which is driven from the gear Ju, is
receiving a vertical reciprocating motion, since the shaft
carrying this gear forms a part of the bobbin carriage;
consequently, some special device must be adopted to keep
the three gears h^, h^, h, constantly in mesh with each other.
Fig. 1 shows simply a diagrammatic view of the gearing of
§25
FLY FRAMES
23
a fly frame, and consequently the device adopted in this
connection is not shown; but by referring to Fig. 9 the
method adopted to compensate for the rise and fall of the
bobbin shaft can be understood. This construction, which is
very frequently adopted on fly frames, is commonly known as
the liorse-head motion. The three gears //s, //«, //, corre-
spond to the same gears in Fig. 1. Swinging loosely on the
bearing that carries the jack-shaft m is an arm z that carries
at its other end a stud on which the intermediate gear h^
revolves. Swinging loosely on this same stud is an arm z^
Fig. 9
that is attached at its opposite end to the bearing of the back
bobbin shaft, on which shaft is the gear //a. This connection
is similar to that between the arm z and the bearing of the
jack-shaft. Since the length of the two arms is always con-
stant and this length is just sufficient to allow the teeth of
the three gears to mesh properly, it will readily be seen
that as the bobbin shaft rises and falls it will necessarily
take the intermediate gear with it and hold it in the correct
position for the teeth of the three gears to mesh properly.
15. Vertical and Angle Shaft Motion. — Another
method of obtaining the same result is shown in Figs. 10
and 11; it is known as the vertical and angle sliaft
motion. The parts of this motion are as follows: A ver-
tical shaft a extends from the under side of the roll beam
almost to the floor, having its lower end pointed and resting
in a footstep and its upper end resting in a bearing that is
24
FLY FRAMES
§25
secured by bolts to the under side of the roll beam. On this
shaft is a sleeve b that extends into the gear-box at the head
of the carriage and is supported by a bracket c and flange b,.
Fig. 10
The sleeve b is key-seated to the vertical shaft, and conse-
quently as the shaft revolves will receive a rotary motion; it
25
FLY FRAMES
25
is, however, free to be moved up and down on the shaft a
as may be desired. It will be seen from the construction
that as the carriage receives its traversing motion it takes
with it the sleeve b, fastened to which is a gear d that gears
into the gear e on the back bobbin shaft. Setscrewed to the
upper end of the vertical shaft <7 is a bevel gear / receiving
motion from the bevel gear g at the upper end of the angle
Fig. 11
shaft //. At the lower end of this angle shaft is another
bevel gear driven by the beveled bobbin gear h^ on a sleeve
on the jack-shaft. By this means the vertical shaft a, which
receives motion from the jack-shaft through the train of
gears just described, is constantly imparting motion to the
gear d on the sleeve b, although this sleeve traverses up and
down the shaft together with the bobbin rail.
26 FLY FRAMES §25
STOP-MOTIONS
16. The full-bobbin stop-motion of a fly frame is
very simple and is found on most fly frames. The shipper
rod a, Fig. 12 {a), extends the entire length of the frame and
passes through the eye of the knock-off lever d, which is
pivoted to a bracket attached to the roll beam. The knock-
oflf lever carries an arm d^ that supports a heavy weight d^,
while near the lower part of the lever is pivoted a knock-off
latch c that passes through an opening in one of the samp-
sons; this Sampson carries a bracket r, that is engaged by a
slot in the latch, thus holding the latch in position. The
rack d, which carries the belt guide e, also has a knock-off
dog dr attached to it by means of a setscrew. A perspective
view of this knock-off dog is shown in Fig. 12 (b).
During the building of the bobbin the cone belt is moved
along the cones by the movement of the rack, which moves
slightly toward the foot end of the frame at the completion
of each traverse. When the bobbins have become full the
belt is at the small end of the top cone and the rack has
moved some distance to the right; consequently, on account
of the position of the knock-off dog on the rack, this dog
passes under the knock-off latch and raises it, thus allowing
the weight di to throw the upper end of the knock-off lever d
to the left so that it strikes the ball «, attached to the shipper
rod. As the lever continues its movement it moves the
shipper rod toward the head end of the frame and ships the
driving belt from the tight to the loose pulley.
The frame can be set to knock off whenever the bobbins
have attained their correct size. This is accomplished by
moving the knock-off dog on the rack so that it will pass
under the latch and release it when the bobbins are of the
desired size.
17. A great deal of trouble and bad work results on fly
frames from the cone belt breaking. In Fig. 12 (a) a patent
knock-off motion is shown, which stops the frame and at the
same time prevents the ends from breaking down at the front
28 FLY FRAMES §25
when the cone belt breaks. The lower cone is supported by
a frame that swings on the back shaft / and is capable of
being raised or lowered; the shaft / is the one that imparts
motion to the racks that actuate the carriage. The chains g,gi
and the rod g^ form a connection between one of the bearings
of the bottom cone and the knock-off latch. The shipper e
carries two belts ^,, e^. The wide belt e^ is the main cone
belt and is used to drive the bottom cone. The belt e^ is a
little longer than <?i, so that it will not come in contact with
the bottom cone when the frame is running properly. When
the belt ^, breaks, the lower cone falls until it comes in con-
tact with the auxiliary belt e^, which is long enough to allow
the lower cone to drop sufficiently to release the latch c by
means of the chain-and-rod connection. When the latch c is
released the knock-off lever forces the shipper rod toward the
head of the frame, so that the belt is moved from the tight
to the loose pulley. The auxiliary belt keeps the lower cone
in motion until the frame has stopped, and thereby prevents
the ends from breaking down at the front.
CREEL
18. Although the slubber has been taken to illustrate the
construction of fly frames, it will be found that the descrip-
tions given will apply equally well to any of the machines
grouped under the head of fly frames. Outside of the differ-
ence in the size of the parts of the different frames, the only
noticeable difference between the slubber and the other
frames is in the manner of feeding the cotton at the back.
As the slubber takes the sliver from the cans that are filled
at the drawing frames, these cans are placed behind the slub-
ber in a similar manner to that adopted at the drawing frames
and other machines to which the cotton is fed from cans. On
the other hand, the roving comes to the later fly frames on
bobbins, and it is consequently necessary to provide some
means by which these bobbins may be supported and yet
allowed to revolve freely as the roving is being unwound
from them. Any arrangement in cotton-mill machinery that
Pig. 13
30
FLY FRAMES
§25
serves to support bobbins or spools is generally termed a
creel. Fig. 13 shows the creel, together with other parts,
of a first intermediate fly frame. The creel consists of a
framework that extends the entire length of the machine at
the back and is built up of the required number of wooden
rails a, a^, a^, a,, which are supported by brackets d that are
setscrewed to the rods c and are capable of being
adjusted up or down in order to have the desired
space between any two. On their upper sides the
rails, with the exception of the top ones, carry glass
cups, or steps, while directly over each cup is a metal
eye d fastened to the rail above. The rods c to which
the brackets d are setscrewed are supported by brack-
ets e bolted to the roll beam; these rods, in addition
to carrying the brackets d, also support small
brackets / through which the rod £■ passes. This rod
serves as a guide for the roving as it is unwound
from the upper bobbins.
In placing the full bobbins in the creel wooden
skewers are used. These skewers are shown at A,
Fig. 13, a skewer alone being shown in Fig. 14.
They are slightly longer than the bobbins and, as
shown in Fig. 13, pass completely through them, the
lower end of each skewer resting in the cup on the top
of the rail, while its upper end passes through the eye
inserted in the edge of the rail above. A shoulder at
the lower end of the skewer prevents the bobbin
from dropping below this position, and as it is prac-
tically only the friction of the bottom point of the
skewer in the glass cup that must be overcome, the
bobbins revolve with a minimum of resistance.
The top of the creel is of sufficient width to sup-
port full bobbins, and it is the custom to place them side by
side and from two to three tiers high along the entire top of
the creel. This provides for a sufficient number of full bob-
bins to take the place of those already in the creel when they
become empty.
Fig. 14
FLY FRAMES
(PART 3)
MANAGEMENT OF FLY FRAMES
CALCULATIONS
1. In connection with fly frames there are numerous
calculations that it is necessary to understand. Many of
these refer to speeds and drafts, on which general informa-
tion and rules have been given in dealing with mechanical and
draft calculations; examples of all necessary calculations are
given in this Section, but the rules dealing with speeds and
drafts are omitted. The examples apply to the gearing
shown in Fig. 1, and to a bobbin-lead type of frame.
Example 1. — Find the speed of the jack-shaft when the main shaft
makes 300 revolutions per minute and carries a 20-inch pulley driving
a 16-inch pulley on the jack-shaft.
300 X 20 „„. • f • 1 u f. A
Solution. — — — = 3/5 rev. per mm. of ]ack-shaft. Ans
lb
Example 2. — Find the revolutions per minute of the top-cone shaft
when the jack-shaft makes 375 revolutions per minute and carries a
38-tooth twist gear driving a 48-tooth gear on the top-cone shaft.
375 X 38
Solution. — — — = 296.875 rev. per min. of top-cone shaft.
48
Ans.
Example 3. — Find the revolutions per minute of the front roll when
the top-cone shaft makes 296.875 revolutions per minute and carries an
86-tooth gear driving a 120-tooth gear on the front-roll shaft. •
296.875X86 „^^ _ . .
Solution.— r-^- = 212. /6 rev. per ram. Ans.
I^or notice of copyright, see page immediately following the title page
§26
^^ I J
§26 FLY FRAMES 3
Example 4. — Find the length of roving delivered per minute by the
front roll when it is 1.25 inches in diameter and makes 212.76 rev-
olutions per minute.
212.76X1.25X3.1416 „ ^^^ . . .
Solution. — ^-, = 23.208 yd. per mm. Ans.
DO
Example 5. — Find the number of revolutions of the spindles to
1 revolution of the jack-shaft when the jack-shaft carries a 42-tooth
gear driving a 42-tooth gear on the spindle-gear shaft, which carries a
46-tooth gear driving a 24-tooth gear on the lower end of the spindle.
1 X 42 X 46
Solution. — — r;^ — = 1.916 rev. of spindles to 1 rev. of jack-
42 X 24
shaft. Ans.
Example 6. — Find the revolutions per minute of the spindles when
the jack-shaft makes 375 revolutions per minute and the spindles make
1.916 turns to one of the jack-shaft.
Solution. — 375 X 1.916 = 718.5 rev. per min. of spindles. Ans.
2. To find the twist, or turns, per inch:
Rule \.— Divide the revohitions per minute of the spindles by
the lejigth of rovijigy in inches, delivered by the frojit roll in the
sa7)ie time.
Ex.\mple 1. — Find the turns per inch being placed in the roving if
the spindles make 718.5 revolutions per minute and the front roll
delivers 23.208 yards per minute.
Solution.— 23.208 X 36 = 835.488 in. per min.; 718.5 -^ 835.488
= .859 turn per in. Ans.
Rule II. — Taking i^ito coiisideration all the gears, with the
exception of the carrier gears, ff^om the front roll to the spindles,
assume that the front-roll gear is a driver. Multiply together
all driving gears aiid divide by the product of all the driven
gears. Divide the guotiejit thus obtained by the circumference of
the fro7it roll.
Ex.\mple 2. — Find the turns per inch being inserted in the roving
with the following arrangement of gears: the front roll is 1.25 inches
in diameter; front-roll gear has 120 teeth; gear on end of top-cone
shaft, 86 teeth; top-cone gear, 48 teeth; twist gear, 38 teeth; jack-shaft
gear, 42 teeth; spindle-shaft gear, 42 teeth, gear on spindle-shaft dri-
ving spindle, 46 teeth; gear on spindle, 24 teeth.
120 X 48 X 42 X 46 „ „„„ 3.378
Solution.- -^^^^^^^^^,^^^^- = 3.3/8; YMx^Jim '' '^^ ^"^"
per in. Ans.
4 FLY FRAMES §26
3. To find the constant for twist:
Rule. — Apply ride II, in Art. 2, tor {i?idhig the twist, con-
sidering the twist gear as a 1-tooth gear.
ExAMPLK — Find the constant for twist, using the train of gearing
given in example 2 in Art. 2 for finding the twist.
^ 120 X 48 X 42 X 46 i„q o^n 128.372
Solution.- -86xO<l2x2r = l'^'^^^; 1.05 x 3.1416 = ^'•^^^-
constant dividend for twist. Ans.
The constant dividend divided by the twist gear equals the twist
per inch; thus, 32.689 -^ 38 = .86, twist per in. Ans.
4. To find the speed of the bobbins:
Rule. — Find the amoimt of roving ivound on the bobbins per
mimcte and divide by the circjimference of the bobbifi. Add the
result thus obtained to the speed of the spindles per minute, and
the atiswer is the speed of the bobbins per minute.
Example 1. — Find the speed of the bobbins at the beginning of a
set when the diameter of the bobbin is 1.75 inches; the speed of the
spindles, 718.5 revolutions per minute; and the front roll delivers
835.488 inches per minute.
835 488
Solution. — r-=^ — ' .,,-,,, = 151.967 rev. per min. of bobbins over
1.75 X 3.141b
speed of spindles. Speed of the spindles, 718.5 rev. per min.; speed
of bobbins over that of the spindles, 151.967. 718.5 + 151.967 = 870.467,
speed of bobbins at beginning of set. Ans.
Example 2. — Find the speed of the bobbins at the finish of a set
when the diameter of the full bobbin is 6.125 inches; the speed of the
spindles, 718.5 revolutions per minute; and the front roll delivers
835.488 inches per minute.
835 488
Solution.— » ^^i J. o -.A^a ~ 43.419 rev. per min. of the bobbins
over the spindles. The number of revolutions per minute of the
spindles is 718.5; the speed of the bobbins over that of the spindles is
43.419. 718.5 + 43.419 = 761.919 rev. per min. of bobbins at the finish
of a set. Ans.
The reduction of the speed per minute of the bobbins
from an empty bobbin to a full bobbin in the above case is
870.467 - 761.919 = 108.548 revolutions.
5. Drafts. — The draft of a fly frame is calculated in the
usual manner.
§26 FLY FRAMES 5
Example 1.— Find the total draft of the rolls shown in Fig. 1, using
a 44 draft gear.
1.25 X 100 X 56 Q Q-7 . . 1 ^ .. A
Solution. — — ., ^^ , . ^^ , — = 3.9^7, total draft. Ans.
40 X 44 X 1
The constant for draft is found in the same manner as
the total draft, except that the draft gear is considered as a
1-tooth gear.
Example 2. — Find the draft constant for the rolls shown in Fig. 1.
1.25 X 100 X 56 _^ ^ ^ .
Solution. — — —r — — lib, constant. Ans.
4U X 1 X 1
Example 3. — Find the draft between the second and third rolls.
1 X 25
Solution. — ~ = 1.086, draft between second and third rolls.
Zo X 1
Ans.
Example 4. — Find the draft between the front and second rolls if
the draft gear contains 44 teeth.
1.25 X 100 X 56 X 23 o .>r^ ^ r ,.
Solution. — — <r> .. <■ .. or .. -• — = 3.659, draft between front
40 X 44 X 25 X 1
and second rolls. Ans.
6. Cliaiige Gears. — In addition to the calculations given
there are several in connection with fly frames that apply-
particularly to the gears that should be used to produce
satisfactory work. It will readily be understood that if a
frame is running on a certain hank roving and it is desired
to change to a different hank, certain gears must be changed
in order that correct results may be obtained. In changing
from one hank to another some or all of the following gears
must be altered (the reference letters apply to Fig. 1):
(1) the twist gear ;;?3, which alters the speed of the rolls
and regulates the t.urns per inch placed in the roving; (2) the
tension gear js, which regulates the movement of the belt
along the cones; (3) the draft gear /, which alters the hank
of the roving delivered; (4) the taper gear x^, which alters
the taper of the bobbin; (5) the lay, or traverse, gear zu,
which alters the speed of the traverse of the carriage.
These are the American names for these gears; the English
builder motion is different from the American and the
English name for tension gear is rack wheel, for taper gear
is taper wheel, and for lay gear is lifter wheel.
6 FLY FRAMES §26
The most important change to make is in the draft change
gear, which regulates the size of the roving. It is generally
customary at the same time to change the twist gear, because
this should vary with every change in the hank of the roving.
The tension gear is also frequently changed. It is not custom-
ary, however, to change the lay gear unless the change in
the hank of the roving is extensive. If the slubber roving is
changed .3 hank, the first intermediate roving .5 hank, the
second intermediate roving .75 hank, or the finished roving
a whole hank, the lay gear will ordinarily be changed.
It is seldom that the taper gear is changed in the mill,
since the gear that is placed on the frame by the builders
usually serves for the range of different hank roving that the
frame is intended to make.
It is important to bear in mind whether an increase or
decrease in the size of a gear must be made to produce
certain results. On the usual construction of American-built
frames, in making a change to produce finer work the draft
gear, the twist gear, the lay gear, and the tension gear would
be changed to smaller gears; on the other hand, if the frame
must be changed to make coarser work, they would be
changed for larger gears, if required to be changed at all.
The same statement is correct with regard to English-built
frames, or American-built frames having an English type of
builder, with the exception of the tension gear, which in case
of changing the frame finer, would be changed to a gear
having a larger number of teeth, or in case of changing the
frame coarser, to a gear having a smaller number of teeth.
The following rules apply to the method of figuring the
different change gears when the gears that are on the frame
and the hank roving being produced are known. From the
calculations previously given it is possible to obtain the draft
and twist gears without this data, but for the tension and lay
gears this data is always necessary, since the correct gear
for starting up a frame was obtained by the builders largely
by experiment and not by calculation. Even when the gear
to use for a certain hank roving is known, the calculated
gear for another hank does not always give satisfactory
1
§26 FLY FRAMES 7
results, since the changing of these gears is largely a matter
of experience and observation, owing to a number of dif-
ferent points affecting the results produced b\^ them, such as
the amount of twist put in the roving, the condition of the
cone belt, the number of times that the roving is wound
around the presser on the flyer, and so forth.
7. To find the draft gear to be used for a certain hank
roving when the draft gear that is on and the hank roving
that it produces are known:
Rule. — Multiply the draft gear being used by the hank
roving that it produces^ and divide the result by the hank roving
that is to be made.
Example. — If 4-hank roving is being produced with a 32-tooth draft
gear, what draft gear will a 6-hank roving require?
Solution.— 32 X 4 = 128; 128 ^ 6 = 21.333, or practically a
21-tooth draft gear. Ans.
8. To find the twist gear to be used for a certain hank
roving when the twist gear that is on and the hank roving
that is produced are known:
Rule. — Multiply the square root of the hank being made by
the twist gear, a7id divide by the square root of the hank required.
In examples in which the diameter of the roving affects
the size of the gear to be used it is necessary to consider the
square roots of the hanks, since the diameters of rovings
vary inversely as the square roots of their hanks.
Example. — If .36-hank roving is being made with a 54-tooth gear,
what twist gear is required for a .64-hank?
Solution.— -^m - .6; \C64 = .8;. 6 X 54 = 32.4; 32.4 ^ .8 = 40.5.
Either a 41-tooth or a 40-tooth gear may be used. Ans.
9. To find the tension gear to be used for a certain hank
roving when the tension gear that is on and the hank roving
that is produced are known, the frame having the American
type of builder:
Rule. — Multiply the sqtiare root of the hank being made by the
tension gear, and divide by the sqjiare root of the ha^ik required.
8 FLY FRAMES §26
Example. — If .36-hank roving is being made with a 50-tooth tension
gear, what tension gear is required for a .64-hank?
Solution.— V^6 = .6; V764 = .8; .6 X 50 = 30; 30 -=- .8 = 37.5.
Either a 37-tooth or a 38-tooth gear may be used. Ans.
To find the tension gear to be used for a certain hank
roving when the tension gear that is on and the hank roving
that is produced are known, the frame having the English
type of builder:
Rule. — Multiply the square root of the hank required by
the iensio?i gear, a?id divide by the sqtcare root of the hank
being made.
Example. — If .36-hank roving is being made with a 20-tooth tension
gear, what tension gear is required for a .64-hank?
Solution.— V73'6 = .6; 4m = .8; .8 X 20 = 16; 16 -^ .6 = 26.666.
A 27-tooth gear would be used. Ans.
10. To find the lay gear to be used for a certain hank
roving when the lay gear that is on and the hank roving that
is produced are known:
Rule. — Multiply the square 7'oot of the hank being made by
the lay gear, and divide by the square root of the hank
reqtdred.
Example. — If .36-hank roving is being made with a 33-tooth gear,
what lay gear is required for a .64-hank?
Solution.— <M = .6; \^ = .8; .6 X 33 = 19.8; 19.8 ^ .8 = 24.75.
A 25-tooth gear should be used. Ans.
11. Production. — To find the production of a fly
frame, in pounds:
Rule. — Multiply the hanks per spiiidle, as indicated by the
hank clock, by the member of spindles, and divide by the hank
roving.
Example. — A clock on a 72-spindle frame registers 75 hanks of
.5-hank roving turned off in a week. What is the production in
pounds?
75 X 72
Solution. — ^ — = 10,800 lb. production. Ans.
§26 FLY FRAMES 9
12. Average Hank.— To find the average hank, or
average number, of the roving when several hanks are
being run:
^xx\Q.— Multiply the Pounds of each hank produced by the
number of the hank, and divide the total of the products thus
obtained by the total of the poimds produced.
ExAMPLE.-If 1,800 pounds of .50-hank, 700 pounds of 1.50-hank
850 pounds of 2-hank, 800 pounds of 2.25-hank, 750 pounds of 4-hank'
and 700 pounds of 10-hank are produced in a week, what is the average
hank of the roving? ^
Solution. —
1800X .5 0= 900
700X 1.5 0= 1050
8 5 X 2.0 = 17
8 X 2.2 5 = 18
750X 4.0 0= 3000
700 X 1 0.0 = 7
Total, 5 6 pounds 15 4 5 hanks
15,450 - 5,600 = 2.758, average hank. Ans.
STARTING FLY FRAMES
13. Draft.— In starting fly frames, one of the first
points to be considered is the arrangement of the drafts in
the different frames. As a general rule, the drafts in the
mtermediate frames should be less than the draft in the roving
frame and slightly greater than that in the slubber. It is not
always possible, however, to arrange a series of fly frames
so as to give the best theoretical drafts, since one process
must keep up with another, and it is customary for those in
charge to change the drafts until the production of one
nicely balances that of the other; that is, if the slubbers are
making too many bobbins for the intermediates, the draft
of the slubber is increased so as to make a finer roving, and
the draft in the intermediates decreased because finer r'o'ving
IS fed at the back, thus making the same hank at the fron't
as in the former case but using a greater length of back
roving. Speaking generally, it may be said that on coarse
work or in mills making below 36s yarn it is best to arrancre
10 FLY FRAMES §26
the draft of the slubber about 4, intermediate about 5, and
the roving frame about 6. The following is an organization
used when starting fly frames for 28s warp and 36s filling.
A 55-grain sliver at the drawing frame (equal to about
.151 hank) and 4.5 draft at the slubber gives .68-hank
slubbing; 5.5 draft at the intermediate, doubling 2^ gives a
1.87-hank roving; and a 6.5 draft at the roving frame, doub-
ling 2, gives a 6.07-hank roving. Other organizations are as
follows: For a 4.5-hank roving at the roving frame, a .5-hank
roving is usually produced at the slubber and a 1. 5-hank
roving at the intermediate, with a draft of 6 at both the
intermediate and roving frames. For a 10-hank roving, the
following are good drafts: slubber, 4; first intermediate, 4.5;
second intermediate, 5; roving frame, 5. For a 20-hank
roving, the following are good drafts: slubber, 4.5; first
intermediate, 5; second intermediate, 6; roving frame, 6.5.
In connection with the drafts in the different fly frames,
an important point always to be taken into consideration is
the production that different drafts will give. In making any
change of hank, it should be clearly understood that chan-
ging to finer roving means reduced production, not only on
account of the reduced weight per yard of the roving, but
also because the speed of the front roll must be reduced in
order to obtain the extra twist that is required for the finer
hank. Sometimes the experiment is tried of putting a
small pulley on the frame so as to bring the speed of the
front roll up to the original speed and increase the speed
of the spindles, but this is not often advisable, as too great
speed makes the work run badly and consequently reduces
the production.
14. Tavist. — Having obtained the correct drafts for the
different frames, the next important point to be considered
is the twist to be placed in the roving. In this connection,
it should be distinctly understood that the amount of twist
in the roving depends on the relation that the speed of the
spindles bears to that of the front rolls. Twist may be
increased in roving either by decreasing the speed of the
§26
FLY FRAMES
11
delivery rolls or increasing the speed of the spindles. The
spindles of each kind of fly frames in a mill are usually run
at a certain number of revolutions per minute, which has been
found most desirable in practice, and any great increase over
this number causes the work to run badly. On this account,
whenever it is desired to insert more twist in the roving, it
is the usual practice to decrease the speed of the front rolls.
This, however, decreases the production of the frame, and
consequently no more twist should be placed in the roving
than is absolutely necessary to allow it to draw off well at
the next process without stretching and breaking. Not only
does any twist above this amount decrease the production,
but it also makes the roving draw badly and is liable to
damage the leather top rolls on the next frame. The amount
of twist placed in roving varies according to the hank being
produced and the stock being used. It has been found prac-
tical to insert a number of turns per inch that is equal to the
product of the square foot of the hank and certain numbers
used as constants. The following table gives the constants
that are commonly used for American, Egyptian, and sea-
island cotton on the slubber, first intermediate, second inter-
mediate, and roving frames.
TABLE I
Cotton
Slubber
First
Inter-
mediate
Second
Inter-
mediate
Roving
Frame
American . . .
Egyptian . . .
Sea-island • . .
I.O
•9
•7
I.I
1.0
.8
1.20
1. 10
.90 to .95
1.3
1.2
1.0
It is generally assumed that a good test for determining
whether sufficient twist is being placed in the roving is to
feel each bobbin to see that it is not too hard or too soft,
although it should be borne in mind that a hard bobbin may
be formed from roving having less than the standard twist if
a presser with a heavy vertical rod is used.
12 FLY FRAMES §26
15. Speed. — It has been stated that the spindles on fly
frames are run at a uniform speed, but in this connection it
may be well to consider what speeds are best for the different
frames. The speed of the spindles on a slubbing frame may
slightly exceed 600 revolutions per minute; on a first inter-
mediate frame 900 revolutions per minute is a good speed;
on a second intermediate, 1,200; and on a roving frame,
1,500 revolutions per minute. These speeds, of course, are
often exceeded in many mills. In some cases it would be
more accurate to give the speeds at 800, 1,000, 1,300, and
1,600 revolutions, respectively, for the four machines.
Experience, however, has demonstrated that in fly frames
high speeds, particularly when the cotton is not up to the
standard, are objectionable. No definite number of revolu-
tions per minute can be given for the spindles of fly frames,
since this is dependent largely on circumstances. It may
sometimes be advisable to run more slowly than the speeds
given above, since old frames, coarse work, or inferior stock
will necessitate slower speeds than new frames, fine work,
or good stock.
When once the correct ratio of speed between the front
roll and the spindle has been found, the only way of increas-
ing production is to increase the speed of the whole frame.
Theoretically, every time the frame is speeded up the produc-
tion ought to increase, although in practice this is not found
to be so, since there is a limit to the speed of every machine
beyond which it is not advisable to go, because an excessive
speed causes unnecessary wear and tear to take place and
results in a large number of ends breaking; this is an espe-
cially important matter in connection with fly frames, since
the whole frame must be stopped to piece one broken end.
16. Build of Bobbin. — After deciding on the draft to
be used in the frame and the number of turns per inch to be
inserted in the roving, a few bobbins may be placed in the
creel, considering that one of the frames other than the
slubber is being dealt with. The ends of roving from two
bobbins are passed through the drawing rolls and pieced at
§26 FLY FRAMES 13
the front. One layer should then be run on the bobbin and
the length of traverse adjusted so as to obtain a layer of as
great a length as possible without the finger of the presser
striking the ends of the bobbin. The proper lay gear may
also be chosen at this point. In order to obtain a well-built
bobbin, the coils in the first layer should be laid so that the
wood of the bobbin can barely be seen between them. Should
the first experimental bobbin show the coils either closer or
farther apart than this, the lay gear should be changed
accordingly. The correct lay gear is largely a matter of exper-
iment and experience, and different millmen have different
ideas as to the correct gear that should be used. For accurate
work, it is advisable to count the number of coils per inch
that are made on the bare bobbin, when satisfactory results
are obtained, for various hanks of roving. From these records
a table of constants can be prepared, which can be used for
reference. It is found in practice that the most suitable
number of coils per inch varies from seven to ten times the
square root of the hank roving being produced, the smaller
multiplier being used for slubbers and intermediates and
the larger one for roving frames. For example, in case of
making 4-hank roving, the square root of which is 2, if 10 is
used as a multiplier, 20 coils per inch will be placed on the
bare bobbin. Other factors enter into the question as to the
spacing of these coils; for instance, the amount of twist
placed in the roving, the grade of cotton being used, and
whether the stock has been carded or both carded and combed,
all have an effect on the number of coils per inch that can
be advantageously placed on the bobbin.
17. Tension. — By referring to Fig. 1, it will be noted
that on the end of the bottom cone is a gear driving, by
means of suitable gearing, a gear on the compound. When
starting up a new frame, it should be carefully noted whether
the roving is running at the correct tension; and if it is not,
this cone gear should be changed until the right tension is
obtained. A gear of fewer teeth will drive the bobbins more
slowly, causing less tension on the ends, while a gear of
14 FLY FRAMES §26
more teeth has the opposite effect. In some cases, instead
of changing the cone gear, the proper tension is obtained by
starting the belt at a different position on the cones. This,
however, is not good practice and should not be allowed.
The belt should always be started at the end of the cones
when winding the first layer on the bobbin, and the cone gear
be of such size as to give the proper tension with the belt in
this position. This cone gear should be changed only when
the frame is being started for the first time, and after the
correct gear has once been obtained it should not be changed
unless the diameter of the empty bobbin is changed. It is
very important to have the tension properly adjusted, since
a difference of from 10 to 15 per cent, in the weight of the
roving on the full bobbin may be made by not having the
correct cone gear, besides causing the frame to produce
unsatisfactory work.
18. Creelinjr. — After the different gears have been put
on and the length of the traverse has been adjusted, the frame
may be considered ready for starting up. The next process is
creeliiijr; that is, placing the bobbins of roving in the creel
at the back of the frame and passing the ends of roving from
them to the rolls. In this connection, it is important to note
that all the bobbins placed in the creel at one time should not
be of the same size, since in this case they would all become
empty at about the same time and thus cause the tender to
replace empty bobbins with full ones in so short a period of
time that it would either necessitate stopping the frame or
result in certain bobbins running empty before full bobbins had
been put in their place. In creeling, it is good practice to put
up two rows of full bobbins and two rows of half-filled bob-
bins, having the roving from one full and one half-filled
bobbin run together, thus causing only a part of the bobbins
to become empty at one time and obviating the difficulty that
arises when the bobbins all run empty at the same time.
Other points to be noted in creeling are that bobbins
should not be inserted that will touch the next bobbin, since
this prevents the easy unwinding of the roving. Sometimes
§26 FLY FRAMES 15
bobbins unwind too freely, resulting in what is known as
overrunning. To prevent this a little piece of cotton is
sometimes inserted under the foot of the skewer to cause
friction and thus retard the rotation of the bobbin. On the
other hand, bobbins containing roving that is too soft are
sometimes placed in the creel at the back of the frame, in
which case the roving breaks instead of unwinding. To
remedy this difficulty the skewers are taken out and sharp-
ened at the bottom so as to lessen the friction.
19. Having pieced up all the ends, the frame may be
started. During the time that the first set is being filled the
different parts of the frame should be carefully watched, espe-
cial notice being taken of the tension on the roving and the
build of the bobbin. Frames vary somewhat in their capacity
for making a w'ell-built bobbin, but as a rule the taper of the
ends of a full bobbin should not be too great, since, if the
slant is too great, it prevents the winding of a sufficient
length of roving on the bobbin and necessitates too fre-
quent creeling at the succeeding processes. On the other
hand, the ends of the bobbin should not be built in such a
manner that they will be almost at right angles with the bob-
bin, since in this case the ends are liable to run under during
winding and thus cause unnecessary breakage of ends.
CARE OF FliY FRAMES
20. Sinsrle and Double. — After the frames have been
well started, several points in the management need careful
attention. Perhaps the most important points are what
are technically known as sinarle and double. These may be
caused in several different w^ays. For example, in fly frames
'that follow the slubber, where two ends are run into one at
the back, it frequently happens that only one end passes
through the guide eye of the traverse rod, while the end that
should be joined to this one runs through a guide eye with
two other ends; thus, instead of having two ends in each
case, in one case there will be a single end and in the
other, three ends. Again, it frequently happens that
16 FLY FRAMES §26
certain of the ends as they leave the delivery rolls at the
front of the frame break, and the strong current of air set up
by the rapidly revolving flyers causes these ends to become
twisted in with an end running on to another bobbin. If the
tender does not notice this at the time it occurs, there is a lia-
bility of several layers of roving being wound on the bobbin
that contain double the thickness that they should. In still
other cases, when an end breaks as it comes from the delivery
roll, it may happen that only part of the roving is twisted in
with the adjoining end, while the other part winds around
one of the rolls, forming what is called a roll lap. All
these cases occur frequently on fly frames and are the
cause of bad work. As will be seen, when double, which is
greater than the required size, for the reasons just given, is
wound on the bobbin, the diameter of the bobbin will be
increased out of its regular proportion, thus causing the
roving to be strained; while on the other hand, in case of
single, which is less than the required size, the diameter of
the bobbin is not increased in its correct proportion, causing
the roving to run slack. When single or double occurs on fly
frames, it is necessary for the tender to stop the frame and
unwind the defective roving from the bobbin. In some cases
so much imperfect roving has been wound on the bobbin that
the correct diameter of the bobbin cannot be obtained in that
set. It then becomes necessary to break out the ends fed to
it, thus causing a spindle to be unproductive throughout the
filling of the rest of the set, and consequently the production
of the frame to be lessened. This is a practice that should
not be allowed, and tenders should be required to watch their
frames carefully for single or double rovings and correct the
defect immediately. If the single or double roving is not
removed from the bobbin, it passes forwards to the next
process and there working in with a perfect end produces
roving or yarn of the wrong number.
21. Piecing:. — The piecing of roving, when broken at
the front, is accomplished as follows: The frame is stopped
and the tender unrolls an arm's length of roving from the
§26 FLY FRAMES 17
bobbin, twisting it slightly by" rolling it between the palms of
the hands in order to give it greater strength. The roving
is then inserted in the hollow leg of the presser by holding
the loose end in one hand and with the other hand sliding the
roving along the slot in the side of the leg. That part of
the roving that passes from the bottom of the hollow leg to the
bobbin is now wound around the presser as many times as
necessary and inserted in the eye of the presser, while the
upper, or loose, end is passed partly around the boss of the
flyer, through the hole in the side of the boss, out at the top,
and overlapped and twisted with the roving projecting from
the front roll. In piecing the roving by twisting in this
manner long piecings should be avoided, since they cause
the yarn to be too thick for some distance. Moreover, hard
piecings should be avoided, since they do not draw well in
the drawing rolls of the next process. After a piecing has
been made, the frame is started slowly; very frequently it
will be found that the end will remain slack for some time.
In such cases it is sometimes the practice for the tender to
retard the motion of the top front roll by pressing it with
the finger or thumb, in order to cause the roving to become
tight. This is not advisable, however, as it causes the
roving for some distance to be thicker than usual; it is pref-
erable to so adjust the bobbin before starting the frame that
there will be as little slack as possible.
22. Doffing. — After a set of bobbins has been filled, it
becomes necessary to remove the full bobbins and replace
them with empty ones. This is known as doffing, and
before the frame is stopped for this operation everything
that is possible should be done to lessen the time to be
devoted to this operation, since it causes a loss of produc-
tion. Such points as having the empty boxes ready for the
full bobbins must be looked out for before stopping the
frame; also where it is possible, as in the case of the slubber
or first intermediate, the empty bobbins should be laid on
the carriage of the frame between the spindles, so that they
will be ready to be placed on the spindles. The operation
18 FLY FRAMES §26
is then as follows: After the frame has stopped, the cone
belt is slackened by raising the bottom cone, so as to reduce
the speed of the bobbin — when the frame is started again —
to the same speed as the flyer and thus prevent any more
roving from being wound on the bobbin; the frame is then
run for an instant in order to cause a few coils of roving to
form at the top of the flyer. The front row of flyers is then
taken off and laid on the top of the top clearer covers, care
being taken not to break the ends of the roving. The full
bobbins are then removed from the front row. of spindles
and each replaced by two empty bobbins, the bottom one
being intended to remain on the front spindles and the other
to be subsequently placed on the back spindles. After
doffing the front row of spindles, the tender doffs the back
row of spindles by lifting the flyer, and replacing the full
bobbin with the extra empty bobbin previously placed on the
front row of spindles. The flyers for the front row of
spindles are then placed in position. The end of roving is
now laid on each bobbin and wound around in such a way
that the outside coils will bind the inner ones, the coils of
roving previously formed at the top of the flyer giving suf-
ficient length to wind around the bobbins to make a new
start. The cone belt is wound back to the other end of the
cones by means of the rack and tightened by lowering the
bottom cone, when the frame is ready to start.
23. Breaking Out. — In some cases, where a very radical
change is made in the number of the yarn to be spun from
the roving, it becomes necessary to make a considerable
change in the hank of the roving being produced by the
different frames. When any considerable change is made in
fly frames, it is generally the custom to run the bobbins that
are in the creel until half of them are almost empty and then
remove all the bobbins from the creel, working them up in
other frames. The creels are refilled with new bobbins of
the correct hank, care being taken that half of them are half
bobbins and that the other half are full bobbins, and the
ends from these new bobbins pieced up to the ends of the
§26 FLY FRAMES 19
old roving projecting from the back roll. These piecings
should be run through to the front and on to a set of empty
bobbins, after which the short lengths should be removed
from the bobbins so as to avoid any piecings or incorrect
roving going forwards to the next process. This entire
operation is technically known as breaking out and is an
expensive process, since it is one that reduces production
very largely; in many mills it is customary when making
only a small change, say from 4-hank to 5-hank or from
10-hank to 12-hank, to do so by merely changing the neces-
sary gears, thus avoiding this process.
24. Oiling. — In order to keep the machines in good
condition, oiling should be carefully attended to; in large
mills, there is usually some person who makes the oiling of
machines his sole occupation. In small mills, it should be
in charge of one of the section hands and not left to the
tender. The rolls or gearing revolving at about the same
speed as the front roll should be oiled every day; the bearings
of the top and bottom cones, the jack-shaft, the horse head,
certain parts of the compound, and all bearings around the
compound, about twice a day. About once a month, the com-
pound should be opened up — that is, slipped apart — and oiled
and cleaned. When high speeds are employed, tallow should
be used on the internal gears of the compound. The amount
of oiling required by the spindle footsteps depends on their
construction, but should be done at least once a month, while
the upper bearings, or bolsters, should be oiled about once
a day. All revolving parts not mentioned should be oiled at
least once a week.
25. Care of Rolls. — The bottom drawing rolls on fly
frames should be scoured at least once in 6 months.
The replacement of old top rolls with new ones is an impor-
tant matter, and it is usual to allow so many rolls a week per
frame or per hundred spindles in the room. This is something
for which no definite rule can be given, as the condition of
the frames, the care of the rolls, the stock being run, and the
hank of the roving all make a difference as to the number of
20 FLY FRAMES §26
rolls that should be allowed. Generally speaking, coarse
roving requires more rolls than fine roving, and old frames
more rolls than new frames. In one mill on medium num-
bers, it is customary to allow three new rolls weekly to each
slubber and each intermediate frame, and four new rolls
weekly to each roving frame. In this connection, it should
be understood that the number of spindles in a roving frame
is about double that in a slubber.
When solid top rolls are used, the rolls that are taken out
of the front row should be moved to the second row and the
rolls from the second row moved to the back row, the rolls
in the back row being taken out to be recovered. In case
the front rolls are shell rolls, which is usual with fly frames
constructed at the present time, new shells replace the old
ones that are taken out to be recovered, while new rolls are
placed in the second row and the rolls taken out of the second
row placed in the back row, the rolls in the back row being
taken out to be recovered. Owing to the fact that the front
rolls revolve at a much greater speed than the back rolls and
that the larger part of the drafting is accomplished between
the two front pairs of rolls, it is possible to run poorer rolls
on the back row without injuring the stock.
26. In order to obtain the best results on fly frames, it is
absolutely necessary that all parts should be kept as clean as
possible. The creels should be brushed out twice every day
and flyers should be wiped at every doflE when running
medium counts; when running fine roving, this should be
done even more frequently. Twice a week the head-end
covers should be taken off and the gearing cleaned. About
once a month, the covers should be taken off the spindle
and bobbin gears and all the waste picked off the gears
and shafts. The head of the flyer should be kept clean and
also the slot in the top of the spindle, so that the pin
will fit accurately in it. Particular care should be taken to
keep the rolls, roll beams, and clearers clean. If the steel
rolls are allowed to become dirty or lapped with cotton they
will produce bad work, frequently resulting in lumpy and
§26 FLY FRAMES 21
uneven roving and causing the ends to break at the succeed-
ing processes. In general, it may be said that the floors of
the room should be kept clean. Waste should be put in its
proper place and not allowed to drop on the floor. Boxes
and baskets should be provided for the empty and full bob-
bins, and should always be kept in their proper places.
COMMON DEFECTS
27. The following are some of the defects frequently
met with in fly frames, together with their remedies:
1. Breaking oi ends between the front roll and the bob-
bins sometimes results from the following causes: twist
gear, draft, or other roll gears slipping or breaking; top-
cone gear slipping; cones becoming loose; cone belt break-
ing; rolls breaking at the joints; spindle- or bobbin-shaft
couplings becoming loose; driving gears at the head of the
bobbin or spindle shafts breaking or becoming loose; bob-
bin, bobbin-shaft, spindle, or spindle-shaft gears breaking
or becoming loose; any obstruction preventing the proper
traverse of the carriage.
2, Slack ends on American-built frames are sometimes
caused by the tension gear being too large. In trying the
tension of the roving it is customary to place the forefinger
under the roving as it is being delivered from the front roll
to the flyer and draw it up slightly until it is tight, judging
the tension in this way. A better way is to get the eye on
a level with the flyer and by glancing from the boss of the
flyer to the front roll note the slackness in the roving. If
there is not quite enough tension, the roving will run all right
for a short length of time, but will then partially curl around
the boss of the flyer, afterwards running along all right again.
If a greater amount of tension is needed, the roving will wind
round the boss of the flyer and break, although this is some-
times caused by the end breaking in the flyer. The tension
of the roving is an important matter and should be carefully
watched at all times, as there are several points that will
affect it. For example, the cone belt may slip because it is
22 FLY FRAMES §26
too slack or too heavily loaded; because the spindle bolsters
are not properly oiled or are allowed to become clogged with
dirt or cotton; because the bolsters are not properh^ adjusted
or are not plumb, thus causing the bolster rail to run hard; or
because the racks bind in the slides. As the lifting motion
is driven through the cones, any drag on the bobbin rail is
liable to cause the belt to slip and thus afiEect the tension.
3. Incorrect Traverse. — Sometimes the clutch gear between
the twin gears becomes loose or has been set wrong, in
which case there will either be no traverse given to the
carriage or the traverse will be imperfect and the roving
that is being delivered will be wound on the bobbin in one
place, thus producing a ridge on the bobbin.
4. Rzinyiing over and under of the roving on the bobbins
is a serious defect, and every means should be adopted to
prevent it. The following are some of the precautions that
should be taken: All gears from builder to carriage must
be in their places and firm on their individual studs and
shafts. The spring at the bottom of the tumbling shaft
must exert its proper tension. If it has not enough tension
to pull the tumbling shaft around so that the teeth on the
gear fixed at its upper end come in contact with the top-cone
gear, it will cause either running over or under of the roving.
The clutch gear situated between the twin gears must be
tight and properly adjusted; the twin gears must also
be properly adjusted and tight on their shaft. Running
over or under is also frequently caused by the carriage not
being perfectly level during its entire traverse. Individual
bobbins are spoiled by the bobbins not being correctly fitted
or not resting properly in their places. At times the pin
breaking in the boss of the flyer will cause the roving to run
under or over either because of the flyer settling down or
because of centrifugal force causing the flyer to rise.
5. Imperfect Flyers. — It is very important that flyers should
be smooth inside and outside at all points where cotton passes
and should fit well on the tops of the spindles so as to obviate
the necessity of hammering them down and thus making them
rough at the top. When the presser on the flyer leg works
§26 FLY FRAMES 23
stiffly and consequently does not exert enough centripetal
pressure on the bobbin, it causes soft bobbins and a weak
roving that will often break when being unwound at the
next process, thus causing annoyance and bad spinning at
the final operation.
6. When the small bevel gear that drives the bobbins is
not properly meshed with the bobbin gear, or when either
gear is worn, it will cause the bobbin to jump and will
break the end or stretch the roving. This may be obviated
by having a systematic inspection of these gears and requir-
ing that such cases be reported at once. Sometimes the
same effect is produced when a bobbin shaft is crooked or
strained, or when a section of the shaft works loose and
slides slightly in its bearings. In this case it will affect
several bobbins. The same is also true of the spindles, in
which case the spindles will jump up and down, instead of
the bobbins.
Sometimes the help after neglecting to piece up an end
promptly, find that the bobbin is too small in diameter to
take up all the roving that has been delivered by the rolls.
In order to remedy this and not to be blamed for running
an empty spindle, they will pack cotton under the weight
hook to cause extra friction on the top roll and reduce its
speed, or they will hold the top roll with one thumb to
attain the same object. This causes two or four ends to be
heavier than the others that are being made, to the extent
of as much as 30 or 40 per cent, for a short distance, which
obviously causes undue variation in the numbers of the yarn at
the spinning room.
SIZING
28. It is customary to test the numbers of roving, or in
other words to size rovinf^, by reeling of? a standard length
from bobbins. The length usually taken in case of slubber
and first intermediate roving is 12 yards; for second inter-
mediate or fine roving, 24 j^ards. The bobbin is placed on a
skewer in a frame usually adjustable for large or small bob-
bins, the end passed through a guide eye to the reel, which is
24 FLY FRAMES §26
18 or 36 inches in circumference, and the desired length
measured off. When this is done the end is broken, the
roving weighed on a small pair of scales known as roving
scales, and the hank of the roving calculated.
In some cases the roving is sized at the drawing frame,
while in other cases the slubber is taken as the starting
point; the roving delivered is weighed two or sometimes
three times a day, two bobbins being taken from a doff.
Twelve yards are reeled off each bobbin and weighed and the
average taken. If the average varies considerably either way
from the correct weight of that number of yards of the hank
being made, the draft gear is changed. These averages are
kept in a special book for this purpose, which can be referred
to at subsequent dates. The bobbins from frames finer than
the slubber are weighed generally once a day, two or even
more bobbins being taken from each frame. Where there is
a difference from the standard of 22 grains in hanks from
1.5 to 4, or a difference of 2 grains in hanks from 4 to 12, a
change is made. After the roving has been weighed, in mills
where a high standard is maintained, a certain number of
bobbins, usually 16, of the different hanks of roving is taken
to the spinning room and the yarn made from them sized and
tested for strength, a record being made and a copy sent to
the overseer of carding. This is the method adopted in fine-
yarn mills; in other mills, the bobbins are not sized so often.
Care should be taken in selecting the bobbins to be sized
that they contain no single or double. Where more than
one frame is on a certain hank or grade of work, the differ-
ent frames should be sized in their turn. If the gear on one
frame is changed on a certain hank or grade of work, all the
frames running under similar conditions should be changed.
This not only applies to roving frames, but to all machines in
a mill where changes must be made.
There are various systems of keeping numbers and various
limits set for the number of grains that roving should be
allowed to vary from either side of the standard before
changing the draft gear. The one explained may be taken
as a basis.
INDEX
Note.— All items in this index refer first to the section and then to the pagre of the
section. Thus, "Brush 18 25" means that brush will be found on page 25 of section 18.
Adjusting points
screw, Evener
the nipper rods
Adjustments, Beater and feed-
roll
Air-current, Regulation of
America, Cotton used in
American and British wires . . . .
cotton
type of builder
Angle shaft and vertical motion .
Apron, Lifting
Arboreum. Gossypium
Arrangement of drawing frame . .
machines
Automatic feeder
Average hank. Rule to find . . . .
B
Back knife plate
Setting the . . .
Bale breaker
breakers. Care of
Baling and ginning cotton
cotton
Barbadense, Gossypium
Barrel. Central
Bars, Grid
Inclined cleaning
grate
Beater, Action of the
and feed-roll adjustments
Doflfer
Beaters. Types of
Blocks, Distance of. from bearings
of detaching roll
Bloom of cotton
Bobbin, Build of
The
Winding the roving on the
Sec.
Pa^ee
20
21
17
35
23
12
17
34
17
39
14
12
19
13
14
13
25
16
25
23
16
20
14
1
21
IS
16
14
16
17
16
26
26
9
18
19
19
67
16
10
16
13
14
16
14
26
14
1
22
22
17
11
17
14
17
14
17
10
17
34
16
23
17
8
'>3
20
14
30
26
12
24
12
24
17
Sec. Page
Bobbins, Mechanisms for control-
ling speed of 25
Method of driving the . . 24
" Rule to find the speed of
the 26
shafts. Methods of driv-
ing 25
Traverse of 24
Bolster, The 24
Bottom rolls 20
Box, Comb 18
Scale 17
Breaker, Bale 16
Floor space of a ... . 17
picker 17
Draft of a ... . 17
pickers 17
Breakers, Care of bale 16
Breaking of ends 26
out 26
British and American wires . ... 19
Brown Egyptian cotton 14
Brush 18
and hackle comb 19
Burnishing 19
tin 22
Builder, American type of .... 25
English type of 25
motions 25
Build of bobbin 26
Burnishing 19
brush 19
Cage sections 17
Calculations, Card cloth 19
Change gear 26
relating to fly frames 26
Speed 18
Calender rolls 22
" Smooth 17
Vll
VIU
INDEX
Cam-shaft
Capacity of automatic feeders . .
Carborundum wheel
Card cloth calculations
clothing
English method of
numbering . . . .
Noggs and points in
construction
cylinders
frame
gearing
Grinding a new
Production of the ...
Roller-and-clearer . . .
room, Management of
Setting the
Carding
beater ,
Double
Cards, Care of
Cotton
Dimensions of
Method of clothing ....
Stripping
Weight and horsepower of
Care of cards
drawing frame
feeders
f^y frames
" machinery, Proper . . . .
" pickers
" rolls
Causes of uneven laps
Central barrel
stock
Change gear calculations
gears
Chisel-point wire
Chute, Waste
Classification and selection of
cotton
Cleaning and oiling pickers ....
the comber . .
bars, Inclined
the stripping roll . . . .
Clearer-and-roller card
Clearers and traverse motions . .
Clocks, Hank
Cloth covering. Method of putting
Sec.
22
16
19
19
19
19
19
18
19
18
18
18
19
18
19
19
19
18
17
19
19
18
19
19
18
19
19
18
19
21
16
26
19
17
26
17
22
22
26
17
25
19
22
on
Roller
Pase
20
27
55
15
9
20
19
3
1
16
26
33
46
42
5
70
56
1
29
1
1
29
42
22
32
42
29
38
27
15
73
39
19
40
22
22
5
37
19
12
25
27
42
28
14
35
5
33
15
Sec. Page
Clothing, Card 19 9
cards. Method of .... 19 22
Cylinder and dofTer ... 19 23
English method of num-
bering card 19 20
Noggs and points in card 19 19
flats 19 22
Coiler 18 31
" head 18 31
Comb box 18 30
Combing by the top .... 22 34
Doffer 18 30
22 25
Setting the doffer 19 69
" stripping .... 19 68
"top 23 10
Timing the top 23 23
Comber, Construction of double-
nip 22 47
Construction of single-
nip 22 13
construction of. Varia-
tions in 22 45
Double-nip 22 47
Gearing of a 22 41
Management of the ... 23 25
" Oiling and cleaning the . 23 28
Principal motions of the 22 15
Purpose of double-nip . 22 47
Single-nip 22 13
Speed of 23 29
Combers 22 1
23 1
Setting various parts of 23 4
Size of gauge settings for 23 3
Combing by the top comb 22 34
Double 23 25
equipment 22 1
operation by the half-lap 22 22
Combs, Flat-stripping 18 24
Common rolls 20 1
Compound motion 25 3
Condenser and gauge box 17 1
Conductors, Electric 21 27
Cones, The 25 13
Connecting sections. Method of . . 20 3
Constant for twist. Rule to find . . 26 4
Constants, Twist 26 11
Construction, Card 18 . 3
Former methods of
card 19 1
of card clothing . . 19 9
"double-nip
comber .... 22 47
" drawing frames 21 IS
" fly frames .... 24 1
INDEX
IX
Sk.
Construction of singrle-nip comber 22
sliver-lap ma-
chine 22
sliver-lap ma-
chine 22
the breaker picker 17
Variations in
comber ... .22
Controlling: speed of bobbins ... 25
Cotton 14
American 14
at the mill, Receipt of . . . 16
Baling 14
Bloom of 14
Brown Egyptian 14
cards 18
" 19
" 19
characteristics, Tables of 14
Classification of 14
cultivation 14
Dampness of 14
Dirt and sand in 14
Exportation of 14
Fair 14
fiber, Measurements of . . 14
Structure of the ... 14
Ginning and baling .... 14
Grade of 14
Growth and development of 14
Gulf, or New Orleans ... 14
Judging 14
Long-stapled 14
Low middling 14
Marketing 14
markets of the United
States 14
Medium-stapled 14
to long-stapled . . 14
Middling 14
AI ill purchases of 14
mixing 16
Varieties of .... 16
Ordinary 14
pickers 17
Principal species of ... . 14
Quantity and quality of . . 14
regions. Productive .... 14
" samples 14
Sea-island 14
Selection of 14
Short-stapled ........ 14
Staple of 14
stock. Condition of .... 16
Testing yarns and fabrics
containing 14
Page
13
45
1
1
13
6
26
30
15
1
1
29
16
27
1
30
29
34
28
8
5
16
28
17
28
27
32
20
18
28
33
6
9
28
1
1
9
10
27
12
27
21'
29
1
Sec. Page
Cotton, Texas 14 15
Uplands 14 14
used in America 14 12
yarn mills 16 2
" Production of .... 16 2
Cottons of the world 14 9
Counts 19 21
Cover, Licker 18 16
Covering for rolls. Leather ... 20 8
Method of putting on
cloth 20 7
Method ofputtingon
leather 20 12
top rolls 20 6
Cradle 23 11
Creel i-s 28
Creeling 26 14
Cultivation, Cotton 14 1
Cushion plate ". . 22 17
settings 2;? 9
Cylinder 22 22
and doffer. Clothing ... 19 23
Grinding the . 19 44
end waste 19 41
screen 18 26
Setting the ... . 19 66
Cylinders, Card is 16
D
Dampness of cotton 14 30
Dead rolls 19 37
Deadweighting 20 25
Defects of fly frames 26 21
Delivery of the stock 22 37
roll 22 26
Timing the motions
of the 23 22
Detaching, Placing rolls in posi-
tion for 23 20
position, Removing de-
taching roll from . . 2:? 22
roll. Distance of blocks
from bearings of . . 23 20
Development and growth of cotton 14 2
Device, Stripping 16 20
Diameter of wire 19 13
Differential motions 25 1
Dimensions of cards 18 42
tiy frames 24 27
Dirt and sand in cotton 14 29
Doflfer 18 27
18 40
and cylinder. Clothing ... 19 23
Grinding the 19 44
beater 16 23
comb 18 30
INDEX
Sec.
Doffer comb 22
" Setting the 19
" Setting the 19
23
Doffing 26
Double-bar traverse motions ... 20
boss rolls 20
" carding 19
combing 23
nip comber 22
Draft 18
gear, Rule to find 26
in fly frames 26
of a breaker picker 17
intermediate and finisher
pickers 17
Drafts of fly frames 26
Draw box 22
" Setting 23
Drawing frame, Arrangement of . 21
Care of 21
" " gearings 21
Space occupied
by a 21
frames 21
and railway
heads 21
" " Management of . 21
" processes. Number of . 21
rolls 20
" Method of driving
the 24
" " of a slubber .... 24
" Settings of 20
Driving bobbin shaft.s 25
the bobbins 24
" drawing rolls 24
" spindles 24
E
Economy of management 19
Egyptian cotton, Brown 14
Electric conductors 21
stop-motion 21
Emery wheel 19
Ends, Breaking of 26
•' Slack 26
English counts 19
" method of numbering card
clothing 19
type of builder 25
Equipment, Combing 22
Evener adjusting screw 17
motion 21
motions 17
Exportation of cotton 14
Page
25
69
64
15
17
39
5
8
25
47
41
7
9
20
39
4
39
16
IS
3S
33
40
17
1
35
17
1
24
5
21
22
26
24
26
F Sec.
Fabrics and yarns containing cot-
ton. Testing 14
Fair cotton 14
Feeder, Automatic 16
16
Feeding and opening machine . . 16
pickers, Methods of . . . 17
Two-roll method of . . . 18
Feed-motion 22
" plate 18
" Setting the 19
" roll 17
" 18
and beater adjustments . 17
Operation of 17
" Setting the top 23
settings 23
rolls 22
" Timing the 23
Fiber, Measurements of the cotton 14
Structure of the cotton . . . 14
Fillet 19
winding machine 19
Filleting 19
Finisher and intermediate pickers 17
and intermediate pickers.
Draft of 17
Flat card, Revolving-top 18
Stationary-top .... 19
point wire 19
stripping combs 18
Flats 18
18
" Clothing 19
Grinding the 19
" Setting the 19
Floor space occupied by drawing
frame 21
of a breaker 17
Fluted segment 22
Flyer, The 24
Flyers, Imperfect 26
Fly frame. Rule to find production
of 26
" frames 24
25
26
Care of 26
Defects of 26
Dimensions of 24
Draft in 26
Drafts of 26
Gearing 24
Horsepower required
to drive 24
Management of .... 26
Page
9
28
17
26
17
1
12
15
34
27
16
6
16
18
8
5
15
25
15
23
39
3
2
12
24
19
40
22
47
57
40
21
22
5
22
8
1
1
1
15
21
27
9
4
24
29
1
INDEX
XI
Ser. Page
Fly frames, Oiling 26 19
Principal motions of . 25 1
Speed of 26 12
Starting 26 9
Footstep bearing 24 9
Formation of the lap 19 8
Frame, Arrangement of drawing . 21 18
Card 18 26
Care of drawing 21 38
Frames, Drawing 21 17
Fly 24 1
^lanagement of drawing . 21 35
Frequency of stripping cards ... 19 33
Front knife plate 18 29
" Setting the ... 19 69
Full-bobbin stop-motion 25 26
" lap stop-motion 22 6
G
Gauge box and condenser 17 1
" settings for combers, Size
of 23 3
Gauges 19 57
Table of A m e r i c a n and
British wire 19 13
used in setting combers . 23 2
Gear calculations. Change .... 26 5
" Index 23 17
" Twist 24 24
(iearing 17 19
Card 18 .33
Fly-frame 24 24
of a comber 22 41
of a picker 17 37
of the automatic feeder . 16 26
Gearings, Drawing-frame 21 33
Gears, Change 17 37
25 19
Twin 25 18
Gin, Knife-roller 14 24
■■ Macarthy 14 25
" Roller 14 24
•• Saw 14 16
(Winning and baling cotton 14 16
Good middling cotton 14 28
ordinary cotton 14 28
Gossypium arboreum 14 1
barbadense 14 1
herbaceum 14 1
hirsutura 14 1
Grade of cotton 14 28
Grate bars. Inclined 17 14
Grid bars 17 11
Grinder. Horsfall 19 38
Traverse 19 38
Grinding 19 36
Grinding a new card
Operation of ....
Plow
Preparation for . .
rolls
the flats 19
•' licker 19
Growth and development of cotton 14
Guide, Traverse
Gulf, or NewOrleens, cotton
H
Hackle comb and brush. Setting
the 19
Half lap 22
Hank clocks 24
Rule to find average .... 26
Head. Coiler 18
Principal parts of the rail-
way 21
Herbaceum, Gossypium 14
Hirsutum, Gossypium 14
Horsehead motion 25
Horsepower and weight of cards . 18
required to draw fly
frames 24
Horsfall grinder . 19
Sec.
Page
19
46
19
44
19
12
19
40
19
36
19
47
19
54
14
2
24
5
14
14
Imperfect flyers
Incorrect traverse
Index gear
Indicator, Speed
Inserting twist. Method of
Intermediate and finisher pickers 17
finisher pickers,
Draft of ... 17
Jack-shaft 24 24
Judging cotton 14 27
K
Knife beater 17 9
" Nipper 22 19
" plate. Back 18 19
Front 18 29
" Setting the 19 67
roller gin 14 25
Knives, Mote 18 14
Lap, Formation of the
'■ Half
" head
" rack
" roll
Weight of 1'
17
7
17
17
17
16
17
41
Xll
INDEX
Laps, Causes of uneven
Lay gear. Rule to find the
Leather covering for rolls
Method of put-
ting on ... .
detaching roll
detaching roll. Setting the
top roll from
Lever-weighting
Licker
cover
Grinding the
screen
Setting the ....
Setting the ^
Licking
Lifting apron
Long-stapled cotton
Medium to
Loose-boss rolls
Low middling cotton
Sec.
17
26
20
M
Macarthy gin
Machine, Feeding and opening . .
Fillet-winding
Ribbon-lap
Sliver-lap
Machinery, Proper care of . . . .
Machines, Arrangement of ... .
Setting of sliver-lap . .
Settings of ribbon-lap .
Making-up pieces
Management, Economy of ....
of card room ....
" " drawing frames .
" " fly frames ....
" the comber room
Marketing cotton
Markets of the United States, Cot-
ton
Measurements of cotton fiber . . .
Measuring motion
Mechanical stop-motions
Mechanism for controlling speed
of bobbins
Medium-stapled cotton
to long-stapled cotton . .
Metallic rolls
Method of driving the bobbins . .
the drawing
rolls
the spindles . .
" feeding. Two-roll . . .
" " inserting twist
Pase
40
Sec. Page
Method of mixing 16 8
Methods of driving bobbin shafts . 25 22
stripping cards .... 19 32
Middling cotton 14 28
fair cotton 14 28
Mill purchases of cotton 14 33
" Receipt of cotton at the ... 16 6
Mills, Object of cotton-yarn ... 16 2
Mixing cotton 16 6
Method of 16 S
Size of the 16 7
varieties of cotton 16 9
Mote knives 18 14
Motion, Compound 25 3
Double-bar traverse ... 20 39
" Evener 21 7
Horsehead 25 22
Measuring 17 32
Piecing-up 22 '25
Vertical and angle shaft . 25 23
Motions, Builder 25 14
Clearers and traverse . . 20 33
Differential 25 1
Evener 17 25
of fly frames 25 1
" the comber 22 15
" delivery roll.
Timing the . . . 23 22
Traverse 20 35
Weight-relieving .... 20 32
N
Needle-ground wire 19 12
point wire 19 12
New card, Grinding a 19 46
Orleans, or Gulf, cotton ... 14 14
Nipper knife 22 19
rods. Adjusting the .... 23 12
Nippers 22 17
Nogg 19 17
Noggs and points in card clothing 19 19
Non-conductors 21 27
Numbering card clothing 19 20
Number of drawing processes . . 21 17
O
Object of combing 22 1
Objects of carding 18 1
Oiling and cleaning pickers .... 17 42
the comber . . 23 28
fly frames 26 19
Opener 16 27
Opening and feeding machine ... 16 17
Operation of feed roll 17 27
" grinding 19 44
'■ ribbon-lap machine . 22 8
INDEX
Xlll
Operation of single-nip comber . . 'Ji
" sliver-lap machine . . '21
" stripping cards ... 19
" the breaker picker . . 17
" ■' electric stop-mo-
tion 21
Operations of the rolls -2
Ordinary cotton 14
P
Pans. Setting sliver
Passage of the stock
Picker. Breaker
Draft of a breaker
Gearing of a
Objects of the breaker . .
rooms
Pickers
" Breaker
Care of
Cotton
Draft of intermediate and
finisher
Intermediate and finisher .
Methods of feeding ....
Pieces, Making-up
Piecing of roving
" up motion
Placing detaching and top rolls in
position
Plate, Back knife
Cushion
Front knife
Setting of the back knife . .
Plow-grinding
Points, Adjusting
and noggs in card clothing
Poker bar
Porcupine beater
Position, Placing detaching and top
rolls in
Preparation for grinding
Principal species of cotton
Principles of carding
Production of a fly frame
" the card
Quality of
Quantity of
Purchases of cotton. Mill
Purpose of double-nip comber . .
Q
Quality and quantity of cotton . .
of production
Quantity of production
and quality of cotton . .
Sfc. PaRf K Sec. Page
22 13 Rack, Lap 17 17
22 3 Rail, Stripping 17 13
19 34 Railway head, Pr in c i pal parts of
17 r> the 21 3
heads and drawing frames 21 1
Recipes for roll varnish 20 13
Regulation of air-current 17 39
Revolving brush 23 14
top flat card IS 3
Ribbon-lap machine 22 S
machines, Settings of 22 11
Rigid-blade beater 17 9
Rods. Adjusting the nipper .... 23 12
Roll, Cleaning the stripping .... 19 3-5
Delivery 22 2t)
" Lap 17 IH
Leather detaching 22 27
" Top 22 29
varnish. Recipes for 20 13
Roller-and-clearer card 19 -5
cloth 20 7
" gin 14 24
Rolls, Advantage of metallic . . 20 17
Bottom 20 1
Calender 22 37
Care of 1f> 19
Common 20 1
Covering top 20 6
Dead 19 37
Double-boss 20 .5
Drawing 20 1
Grinding 19 36
Leather covering for .... 20 8
Loose-boss 20 ,5
'■ Metallic 20 15
Method of driving the draw-
ing 24 24
of a slubber. Drawing ... 24 .5
Operations of the 22 29
Rules governing setting of . 20 is
Scouring 20 39
Setting and weighting ... 20 IS
top 20 24
Settings of drawing .... 20 21
Single-boss 20 .t
Smooth calender 17 16
Solid-boss 20 5
" Top 20 4
Room, Management of the comber 23 2.5
Rooms, Location of picker .... 16 14
Picker 16 13
Roving on the bobbin. Winding
14 9 the 24 17
19 70 " Piecing of 26 16
19 72 " Running over and under
14 9 of the 26 22
XIV
INDEX
Sec. Page
Roving scales 26 24
Tension of 26 13
Rule to find average hank 26 9
" find production of a fly
frame 26 8
" find the constant for twist 26 4
" find the draft gear .... 26 7
" find the lay gear 26 8
find the length of filleting
for cylinder dofTer .... 10 2.5
" find the number of sec-
tions of a mixing .... 16 8
" find the points per square
foot of card clothing . . 19 17
" find the speed of the bob-
bins 36 4
" find the tension gear ... 26 7
'■ find the twist gear 26 7
Rules governing setting of rolls . . 20 IS
to find the twists or turns
per inch 26 3
Running over and under of the
roving 26 22
S
Samples, Cotton 14 27
Sand and dirt in cotton 14 29
Saw gin 14 16
Scale box 17 2.5
Scales, Roving 26 24
Scouring rolls 20 39
Screen. Cylinder 18 26
Licker 18 16
Setting the cylinder . ... 19 66
" licker 19 67
Screw, Evener adjusting 17 35
Sea-island cotton 14 12
Sections, Method of connecting . . 20 3
Segment, Fluted 22 22
Selection of cotton 14 27
■■ skins 20 10
Self-weighting 20 25
Setting and timing combers .... 23 1
" weighting rolls .... 20 is
combers 23 2
draw box 23 16
of rolls. Rules governing. 20 18
sliver pans 23 16
the back knife plate .... 19 67
" brush and hackle comb 19 69
" card 19 .56
" cylinder screen .... 19 66
" doffer 19 64
23 15
comb 19 69
" feed-plate 19 66
Setting the flats
" front knife plate . . . .
" grid bars
" licker
screen
" stripping comb . . . .
" top comb
" top feed-roll
"top roll from leather
detaching roll ....
" various parts of comb-
ers
Sec.
Page
19
57
19
68
17
12
19
64
19
67
19
68
23
10
23
16
23 21
top rolls
Settings, Cushion plate
Feed-roll
for combers. Size of
gauge ,
Minor
of drawing rolls
" ribbon-lap machines .
" sliver-lap machines .
Shafts. Methods of driving bobbin
Short-stapled cotton
Side-ground wire
Single-boss rolls
nip comber
Size of gauge settings for combers
" the mixing
Sizing
Skins, Selection of
Slack ends
Sliver
lap machine
" machines, Settings of . .
pans. Setting
stop-motion
Slubber, Drawing rolls of a ... .
The
Smooth calender rolls
Solid-boss rolls
Speed of fly frames
Spindles, Method of driving the . .
Splitting
Species of cotton. Principal ....
Speed calculations
indicator
of bobbins. Mechanisms for
controlling
" comber
" the bobbins
Speeders
Spindle, The
Staple of cotton
Starting fly frames
Stationary-top flat card
Stock, Central
23
4
20
24
23
9
23
6
23
3
23
12
20
21
22
11
22
6
25
22
14
21
19
T?
20
5
22
13
23
3
16
7
26
23
20
10
26
21
18
2
22
3
22
6
23
16
22
6
24
5
24
4
17
16
20
5
26
12
24
26
17
40
14
1
18
39
19
75
25
1
23
29
26
4
24
2
24
8
14
29
26
9
19
2
22
22
INDEX
XV
Sec.
Page
stock, Condition of cotton ....
16
1
Delivery of the
22
37
Passage of the
22
14
" "
24
4
Stop-motion, Electric
21
26
Full-bobbin
2,'i
26
Full-lap
22
6
" " Operation of the elec-
tric
21
28
" motions
21
23
25
26
Sliver
22
6
Stripping cards
19
32
comb. Setting the ....
19
68
device
16
20
rail
17
13
roll. Cleaning the ....
19
35
Structure of the cotton fiber . . .
14
5
T
Table of American and British
wire gauges
19
13
'i cushion plate settings .
23
9
" dimensions of fly
frames
24
28
" English counts
19
22
" feed-roll settings ....
23
6
" " gauge settings for com-
23
3
" " horsepower required
to draw fly frames . .
24
29
" long-stapled cotton . .
14
17
" medium-stapled cotton
14
20
" " " to long-stapled
cotton . . .
14
18
" " noggs and points in
card clothing . . . .
19
19
" " settings of drawing rolls
20
21
" short-stapled cotton . .
Xi
21
" twist constants ....
26
11
'" " weights of lap
17
41
Tables of cotton characteristics
14
16
Teeth
19
26
11
Tension gear. Rule to find the . .
of roving
26
13
Testing yarns and fabrics contain-
ing cotton
14
9
Texas cotton
14
15
o-^
17
and setting combers . . .
23
1
the feed
23
18
" motions of the delivery
roll
0-^
22
" nippers
23
18
" top comb
23
23
Tin, Brush
22
2P
Top comb. Combing by the ....
Setting the
Timing the
ground wire
roll
" in position, Placing the . .
" from leather detaching
roll, Setting the
" weighting
rolls
Covering
" Setting
Traverse grinder
guide .
Incorrect •.
motions ...
" " Double-bar . .
of bobbins
Trunk, Horizontal cleaning ....
Plain conducting
Trunking
Trunks. Inclined cleaning . .
Turns or twists per inch. To find
Twin gears
Twist
gear
Rule to find
Method of inserting ....
Ru,le to find the constant for
Twists or turns per inch .....
Two-roll method of feeding ....
Type of builder, American ....
English
Types of beaters
U
Uneven laps. Causes of 17
United States, Cotton markets of
the 14
Uplands cotton 14
Variations in comber construction 22
Varieties of cotton, Mi,xing differ-
ent 16
Varnishing 20
Vertical and angle shaft motion . . 25
W
Waste 18
23
chute 22
Cylinder-end 19
Weight and horsepower of cards 18
relieving motions 20
'Veighting and setting rolls .... 20
Sff.
/'age
22
34
23
10
23
23
19
12
22
29
23
20
23
21
20
24
20
4
20
6
20
24
19
38
24
5
26
22
20
35
20
39
24
21
16
28
16
28
16
28
16
30
26
3
25
18
26
10
24
. 24
26
7
24
16
26
4
26
3
18
12
25
16
25
20
17
8
XVI
INDEX
Weighting:. Top-roll 20
Weights of lap 17
Wheel, Carborundum 19
" Emery 19
Winding the roving on the bobbin 24
Wire, Chisel-point 19
Diameter of 19
Flat-point 19
Needle-ground 19
point 19
Sec. Page Sec. Page
24 Wire, Side-ground 19 12
41 " Top-ground 19 12
55 Wiregauges, British and American 19 13
54 World, Cottons of the 14 9
Y
Yarn-preparation processes ... 16 1
Production of cotton ... 16 2
Yarns and fabrics containing cot-
ton, Testing 14 9
cyr/^-so
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